U.S. patent application number 15/823717 was filed with the patent office on 2018-03-22 for novel methods for producing crystalline microporous solids with the rth topology and compositions derived from the same.
The applicant listed for this patent is CALIFORNIA INSTITUTE OF TECHNOLOGY. Invention is credited to MARK E. DAVIS, JOEL E. SCHMIDT.
Application Number | 20180079651 15/823717 |
Document ID | / |
Family ID | 53543950 |
Filed Date | 2018-03-22 |
United States Patent
Application |
20180079651 |
Kind Code |
A1 |
SCHMIDT; JOEL E. ; et
al. |
March 22, 2018 |
NOVEL METHODS FOR PRODUCING CRYSTALLINE MICROPOROUS SOLIDS WITH THE
RTH TOPOLOGY AND COMPOSITIONS DERIVED FROM THE SAME
Abstract
This disclosure relates to new crystalline microporous solids
(including silicate- and aluminosilicate-based solids), the
compositions comprising 8 and 10 membered inorganic rings,
particularly those having RTH topologies having a range of Si:Al
ratios, methods of preparing these and known crystalline
microporous solids using certain quaternized imidazolium cation
structuring agents.
Inventors: |
SCHMIDT; JOEL E.; (PASADENA,
CA) ; DAVIS; MARK E.; (PASADENA, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CALIFORNIA INSTITUTE OF TECHNOLOGY |
Pasadena |
CA |
US |
|
|
Family ID: |
53543950 |
Appl. No.: |
15/823717 |
Filed: |
November 28, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14602415 |
Jan 22, 2015 |
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15823717 |
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61930326 |
Jan 22, 2014 |
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61969963 |
Mar 25, 2014 |
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62013167 |
Jun 17, 2014 |
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62054247 |
Sep 23, 2014 |
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62077719 |
Nov 10, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01D 2257/404 20130101;
B01J 29/85 20130101; C01B 39/065 20130101; C07C 209/16 20130101;
B01J 29/89 20130101; B01D 2253/1124 20130101; B01J 29/7015
20130101; B01J 37/08 20130101; B01J 29/76 20130101; C01B 39/06
20130101; C10G 47/04 20130101; Y02P 30/40 20151101; B01J 29/041
20130101; C01B 39/48 20130101; C07C 5/2775 20130101; C10G 11/05
20130101; C10G 35/065 20130101; B01J 29/78 20130101; C01B 39/00
20130101; C01B 39/087 20130101; C07C 2/00 20130101; C10G 47/16
20130101; C07C 67/37 20130101; B01J 29/74 20130101; C01B 39/085
20130101; B01J 29/072 20130101; C07C 5/2518 20130101; C07C 5/2737
20130101; B01D 2253/106 20130101; B01J 29/061 20130101; B01J 37/082
20130101; B01J 29/068 20130101; Y02P 30/20 20151101; B01J 29/72
20130101; B01J 29/87 20130101; C01B 39/082 20130101; C07C 1/20
20130101; C07C 209/14 20130101; C07C 2/12 20130101; C07C 2529/70
20130101; B01D 2253/108 20130101; B01J 29/035 20130101; C10G 35/00
20130101; Y02P 30/42 20151101; B01D 53/02 20130101; B01J 29/86
20130101; C10G 49/08 20130101; B01J 29/70 20130101; C01B 39/08
20130101; B01J 29/064 20130101; B01D 2253/20 20130101; C01B 39/12
20130101; C10G 50/00 20130101; B01D 2253/1085 20130101; C07C 6/06
20130101; B01J 29/88 20130101; C10G 29/205 20130101; C07C 7/13
20130101; B01D 2256/12 20130101; B01D 2257/102 20130101; C07C
209/16 20130101; C07C 211/04 20130101; C07C 67/37 20130101; C07C
69/14 20130101; C07C 69/14 20130101; C07C 1/20 20130101; C07C 1/20
20130101; C07C 11/02 20130101 |
International
Class: |
C01B 39/48 20060101
C01B039/48; C01B 39/08 20060101 C01B039/08; B01J 29/04 20060101
B01J029/04; B01J 29/068 20060101 B01J029/068; B01J 29/072 20060101
B01J029/072; B01J 29/064 20060101 B01J029/064; C01B 39/06 20060101
C01B039/06; B01J 29/06 20060101 B01J029/06; B01J 29/87 20060101
B01J029/87; C01B 39/12 20060101 C01B039/12; B01J 29/88 20060101
B01J029/88; B01J 29/86 20060101 B01J029/86; B01J 29/70 20060101
B01J029/70; C07C 209/16 20060101 C07C209/16; B01J 29/89 20060101
B01J029/89; B01J 37/08 20060101 B01J037/08; C07C 209/14 20060101
C07C209/14; C10G 47/04 20060101 C10G047/04; C07C 7/13 20060101
C07C007/13; C07C 6/06 20060101 C07C006/06; C10G 50/00 20060101
C10G050/00; C10G 49/08 20060101 C10G049/08; C10G 47/16 20060101
C10G047/16; C10G 35/06 20060101 C10G035/06; C10G 29/20 20060101
C10G029/20 |
Claims
1. A process for preparing a crystalline microporous solid of RTH
topology, the process comprising hydrothermally treating a
composition comprising: (a) (i) at least one source of silicon
oxide and (ii) at least one source of aluminum oxide, boron oxide,
gallium oxide, hafnium oxide, iron oxide, tin oxide, titanium
oxide, indium oxide, vanadium oxide, zirconium oxide, or
combination or mixture thereof in the presence of an organic
complex comprising (b) an imidazolium cation comprising methyl and
ethyl groups and having a C/N+ ratio in a range of from 6:1 to
10:1; and (c) an associated hydroxide or fluoride anion; under
conditions effective to crystallize the crystalline microporous
solid of RTH topology.
2. The process of claim 1, comprising hydrothermally treating a
composition comprising (a) (i) at least one source of a silicon
oxide, germanium oxide, or combination thereof; (ii) at least one
source of aluminum oxide; and optionally (iii) at least one source
of boron oxide, gallium oxide, hafnium oxide, iron oxide, tin
oxide, titanium oxide, indium oxide, vanadium oxide, zirconium
oxide, or combination or mixture thereof and (b) an imidazolium
cation comprising methyl and ethyl groups and having a C/N+ ratio
in a range of from 6:1 to 8:1 and an associated hydroxide or
fluoride anion, under conditions effective to crystallize a
crystalline microporous aluminosilicate solid of RTH topology.
3. The process of claim 1, wherein the imidazolium cation is
described by a resonance form that is: ##STR00034##
4. The process of claim 1, wherein the source of silicon oxide
comprises a silicate, silica hydrogel, silicic acid, fumed silica,
colloidal silica, tetra-alkyl orthosilicate, a silica hydroxide or
combination thereof.
5. The process of claim 1, wherein the source of aluminum oxide
comprises an alkoxide, hydroxide, or oxide of aluminum, a sodium
aluminate, an aluminum siloxide, or combination thereof.
6. The process of claim 1, wherein the source of boron oxide,
gallium oxide, hafnium oxide, iron oxide, tin oxide, titanium
oxide, indium oxide, vanadium oxide, zirconium oxide, or
combination or mixture thereof comprises an alkoxide, hydroxide,
oxide, or combination thereof of the corresponding metal.
7. The process of claim 1, wherein the ratio of Si:Al in the
composition is in a range of from about 5:1 to about 250:1.
8. The process of claim 1, further comprising aqueous HF.
9. The process of claim 1, further comprising aqueous
hydroxide.
10. The process of claim 8, wherein the ratio of imidazolium
cation:Si is in a range of from about 0.0.2:1 to about 1:1.
11. The process of claim 9, wherein the ratio of imidazolium
cation:Si is in a range of from about 0.05 to about 1:1.
12. The process of claim 8, wherein the ratio of water:Si is in a
range of from about 2:1 to about 20:1.
13. The process of claim 9, wherein the ratio of water:Si is in a
range of from about 2:1 to about 40:1.
14. The process of claim 1, wherein the hydrothermally treating is
done at a temperature in a range of from about 100.degree. C. to
about 200.degree. C. for a time effective for crystallizing the
crystalline microporous solid.
15. The process of claim 1, further comprising isolating the
crystalline microporous solid.
16. The process of claim 15, further comprising calcining the
crystalline microporous solid at a temperature in a range of from
about 350.degree. C. to about 850.degree. C.
17. The process of claim 16, further comprising treating the
calcined material with an aqueous ammonium salt.
18. The process of claim 16, further comprising treating the
calcined crystalline microporous solid with at least one transition
metal or transition metal oxide.
19. The process of claim 18, wherein the at least one transition
metal or transition metal oxide comprises scandium, yttrium,
titanium, zirconium, vanadium, manganese, chromium, molybdenum,
tungsten, iron, ruthenium, osmium, cobalt, rhodium, iridium,
nickel, palladium, platinum, copper, silver, gold, or a mixture
thereof.
20. The process of claim 16, further comprising treating the
calcined crystalline microporous solid with at least one at least
one cation of a Group 1, Group 2, or Group 8 metal.
21. The process of claim 20, wherein the at least one cation of a
Group 1, Group 2, or Group 8 metal is a rare earth metal, Mn, Ca,
Mg, Zn, Cd, Pt, Pd, Ni, Co, Ti, Al, Sn, Fe, or a mixture thereof.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent
application Ser. No. 14/602,415, filed Jan. 22, 2015 which claims
the benefit of priority to U.S. Provisional Patent Application Nos.
61/930,326, filed Jan. 22, 2014; 61/969,963, filed Mar. 25, 2014;
62/013,167, filed Jun. 17, 2014; 62/054,247, filed Sep. 23, 2014;
and 62/077,719, filed Nov. 10, 2014, the contents of each of which
are incorporated by reference in their entirety herein.
TECHNICAL FIELD
[0002] This disclosure relates to new crystalline microporous
solids (including silicate- and aluminosilicate-, and other
metal-silicate-based solids), the various compositions comprising
8, 10, 12, and 14-membered inorganic rings, particularly those
having RTH, HEU, CIT-7, and IWV topologies having a wide range of
Si:Al ratios. This disclosure also provides methods of preparing
these and known crystalline microporous solids using certain
quaternized imidazolium cation organic structure directing agents,
and intermediates used in these methods.
BACKGROUND
[0003] It is estimated that over 90% of chemical processes use a
catalyst, with 80% being a heterogeneous catalyst, with a global
demand of $15 to $20 billion per year. Microporous materials (pores
less than 2 nm) are an important type of heterogeneous catalyst as
they offer shape and size selective environments for catalysis to
occur. Additionally, they often exhibit robust hydrothermal
stability which allows them to be used under demanding process
conditions, such as fluid catalytic cracking. Synthetic
aluminosilicate zeolites are produced on a scale 1.7-2 million
metric tons per year, and their use as catalysts comprises 27% of
the world market for zeolites. As the cost of the catalyst is
estimated to be only 0.1% of the cost of the final product, the
demand to innovate in this area remains high. There currently exist
over 200 known microporous material frameworks, but of these less
than 20 have been commercialized and the market is dominated by
only five major frameworks. In many applications, there is only a
single structure and composition to achieve optimal performance,
motivating much of the research directed at creating new
materials.
[0004] In recent years there has been considerable interest in 8-MR
systems for catalysis and separations. Some of the most promising
catalytic applications are the methanol to olefins (MTO) conversion
and deNOx. Other 8-MR materials of interest are LEV, CHA and AFX.
It has been found that the cage size and connectivity are critical
in determining the product distribution for these reactions in 8-MR
systems. As RTH possesses a unique connectivity as well as cage
size it exhibits unique catalytic performance, which has been shown
for MTO using the aluminosilicate material. The RTH topology has
8-MR openings and a 2-dimensional ("2-D") channel system with pore
sizes of 4.1.times.3.8 .ANG. and 5.6.times.2.5 .ANG., leading to
larger cages. See also C. Baerlocher, L. B. Mccusker, Database of
Zeolite Structures, approved by the Structure Commission of the
International Zeolite Association, and available at
<http://www.izastructure.org/databases/>, (2014).
[0005] The molecular sieve (zeolite) with the framework topology of
RTH was first described in 1995. It was produced as a borosilicate
(RUB-13) using the relatively simple organic structure directing
agent ("OSDA") 1,2,2,6,6-pentamethylpiperidinium. Although the
borosilicate requires a less exotic OSDA, the small pores of the
material prevent the replacement of boron with aluminum. However,
in order to produce an aluminosilicate material with the necessary
acid strength for the MTO reaction, a more complicated OSDA was
required. The next RTH microporous material was produced as an
aluminosilicate (SSZ-50) using
2-ethyl-2,5,7,7-tetramethyl-2-azabicyclo[4.1.1]octan-2-ium as the
structure directing agent.
##STR00001##
But this OSDA requires an elaborate multi-step synthesis adding to
the cost and complexity of the preparation, so as to be unlikely
this material would be used in commercial production. Some progress
has been made to synthesize a OSDA-free version of RTH using seed
crystals, but materials so-produced have a very limited
compositional range. Additionally, the high Si/Al ratios (Si/Al=41
and 108) may be less than optimal for a catalyst. For all of these
reasons an alternative SDA to produce RTH is desired so that it can
be tested for applications.
[0006] Microporous solids having 2-dimensional channels and 8-MR
and 8-/10-MR frameworks are finding increasing utility as
catalysts, ion exchange, and adsorption systems. The heulandite
(HEU) framework is another topology having a 2-dimensional channel
system, and relatively large pore sizes. In the [001] directing
there are 10-membered rings (MRs) as well as 8-MRs. Additionally,
there is another set of 8-MRs along with [100] direction.
[0007] Heulandite materials are divided into two distinct classes
based on Si/Al ratio. Those with Si/Al of less than 4 are known as
heulandite and those with Si/Al greater than 4 are known as
clinoptilolite, or silica-rich heulandite. The key difference in
these materials is that those with Si/Al of less than 4 are not
thermally stable to calcination above 350.degree. C. A method to
produce a high-silica heulandite was first reported by removing
aluminum from natural clinoptilolite to make a material with
Si/Al=5.5, known as LZ-219. Later, methods were developed to
produce synthetic heulandite across a range of Si/Al=2.5-6 using
various sources of silica and alumina and a wide range of inorganic
cations (Li, Na, K, Rb, Ca) under hydrothermal synthesis (without
the use of OSDAs) or acid leaching conditions. These materials have
been considered for applications such as gas cleaning and
separations, ion exchange, isomerization of 1-butene and xylene,
methanol dehydration and acetylene hydration. In any of these
applications, the ability to tailor the framework composition is
important for material properties such as exchange capacity,
hydrothermal stability and pore accessibility.
[0008] Crystalline microporous solids of the IWV framework were
first prepared as the ITQ-27 framework using the
phosphorus-containing structure-directing agent,
dimethyldiphenylphosphonium. Its structure comprises seven unique
T-sites forming a framework with straight 12-MR channels that are
connected by 14-MR openings between them. Since access from one
14-MR opening to the next is through the 12-MR channel, the
structure is best described as a two-dimensional, 12-MR framework.
Other ITQ structures are known to have larger (e.g., 12-/14-MR) and
smaller ring openings, making these materials useful for
hydrocarbon processing.
[0009] Much of the discovery of new microporous material frameworks
and compositions in recent years has resulted from the use of
organic structure directing agents (OSDAs), which are normally
alkylammonium cations. While OSDAs have led to many new materials,
their cost contributes a significant portion of the material cost,
which often cannot be recovered as they are normally removed from
the material using combustion. In some systems it is possible to
partially replace high cost OSDAs with cheaper organics, such as
with SSZ-13 where it has been shown that over 80% of the expensive
trimethyl-N-1-adamantammonium hydroxide OSDA can be replaced with
the much cheaper benzyl trimethyl ammonium hydroxide. Another way
is to find methods to synthesize the materials in the absence of
OSDAs, but this can often lead to limited product compositions and
still does not eliminate processing steps such as ion exchange and
calcination. Therefore, an attractive route to lower OSDA costs is
to find new, simpler OSDAs to synthesize desired materials.
[0010] For at least these reasons, interest is currently high in
developing new molecular sieves having 2-dimensional channel
systems with 8-MR and 8-/10-MR openings and 12-MR openings.
SUMMARY
[0011] The present invention is directed to several new crystalline
microporous solids, having 2-dimensional channel systems with 8-MR,
8-/10-MR, and 12-MR channels, and methods of preparing the same.
One set comprises crystalline material having an RTH topology
generally (including SSZ-50), and especially aluminosilicate
compositions having low Si:Al ratios, and methods for preparing
these types of materials across a wide range of Si/Al including low
Si/Al ratios. A second set, described herein as CIT-7, is a new
crystal form, and includes a broad range of compositions having
2-dimensional channels with 8-MR and 10-MR. A third set of
materials comprises solids having HEU topology, having 2
dimensional channels and 8-MR and 8-/10-MR openings, especially
aluminosilicate materials having high Si:Al ratios. High silica
HEU, denoted CIT-8 (California Institute of Technology number 8)
can be prepared via topotactic condensation of a layered
aluminosilicate material containing an organic structure directing
agent. This layered material is denoted CIT-8P. CIT-8 can also be
prepared by direct synthesis in hydroxide media using an
imidazolium organic structure directing agent (OSDA). A fourth
material, which has the IWV framework structure contains a
2-dimensional system of 12-MR channels, which lead to internal
14-MR rings and is prepared at previously unknown compositions.
[0012] Also described are the processes and intermediates used in
making such compositions. Such compositions and methods include the
use of organic structure defining agents (OSDAs) including
quaternized imidazolium cations ("quats") and linked pairs of
quaternary imidazolium cations ("diquats"). These materials have
shown good activity for the methanol-to-olefins reaction (MTO) and
have also been proposed as a material for catalytic NOx reduction.
Industrially, imidazoles are produced using the Radziszewski
reaction or by dehydrogenation of imidazolines and are available in
high purity. The quaternary imidazolium cations of the present
invention can then be prepared by standard alkylation methods.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present application is further understood when read in
conjunction with the appended drawings. For the purpose of
illustrating the subject matter, there are shown in the drawings
exemplary embodiments of the subject matter; however, the presently
disclosed subject matter is not limited to the specific methods,
processes, devices, and systems disclosed. In addition, the
drawings are not necessarily drawn to scale. In the drawings:
[0014] FIG. 1 shows representative powder X-ray diffraction (XRD)
patterns of one of the RTH compositions produced by the present
methods: as-made (lower) and calcined (upper) aluminosilicate RTH
zeolites for composition prepared using 1 SiO.sub.2: 0.5 Al: 0.5
ROH: 0.5 HF: 14 H.sub.2O, where ROH is pentamethylimidazolium
hydroxide.
[0015] FIG. 2 shows representative powder X-ray diffraction (XRD)
patterns for calcined aluminosilicate RTH prepared in hydroxide
media (sample H4), as described in Example 4.
[0016] FIG. 3 and FIG. 4A-C show Scanning Electron Micrographs
(SEMs) for materials prepared in Example 1.3. FIG. 4A shows SEM of
calcined RTH prepared in fluoride media (sample F4). FIG. 4B shows
SEM of calcined RTH synthesized in hydroxide media with sodium
(sample H4). FIG. 4C shows SEM of calcined RTH synthesized in
hydroxide media without sodium (sample H5).
[0017] FIG. 5 shows a .sup.13C NMR spectra of
pentamethylimidazolium in D.sub.2O with methanol standard (lower),
.sup.13C CP-MAS NMR of as-made RTH prepared in hydroxide media
(middle, sample H4) and .sup.13C CP-MAS NMR of as-made RTH prepared
in fluoride media (upper, sample F4).
[0018] FIG. 6 shows .sup.27Al MAS NMR spectra of low silica RTH
synthesized in hydroxide media (lower, sample H1) and prepared in
fluoride media (upper, sample F2). The single resonance is at 54
ppm.
[0019] FIG. 7 show an argon isotherm for aluminosilicate RTH
prepared in hydroxide media with product Si/Al=14 (sample H4).
[0020] FIG. 8A-G shows MTO reactivity data for various compositions
described herein. FIG. 8A shows data for SSZ-13 with Si/Al=19; FIG.
8B shows data for SAPO-34; FIG. 8C shows data for fresh Si/Al=17
RTH (sample H6); FIG. 8D shows data for Si/Al=17 RTH (sample H6;
regenerated one time); FIG. 8E shows data for Si/Al=17 RTH (sample
H6; regenerated two times); FIG. 8F shows data for Si/Al=29 RTH
(sample H8); FIG. 8G shows data for Si/Al=59 (sample H10), showing
methanol conversion (open diamonds) to C.sub.2 olefins (solid
squares), C.sub.3 olefins (solid triangles), C.sub.4 olefins (solid
diamonds), total C.sub.1-C.sub.4 alkanes (open circles), and
C.sub.5's+C.sub.6's (solid circles).
[0021] FIGS. 9A and 9B shows representative powder X-ray
diffraction (XRD) patterns for calcined pure silicate RTH prepared
in fluoride. The patterns are for the as-made material (FIG. 9A,
lower), material treated with ozone at 150.degree. C. to remove the
organic (FIG. 9A, middle) and calcined material (FIG. 9A, upper and
FIG. 9B).
[0022] FIG. 10 shows representative powder X-ray diffraction (XRD)
pattern for calcined pure silica CIT-7 material (made with
2-ethyl-1,3-dimethylimidazolium cation) containing an ITW impurity,
marked with *. See Example 8.1.
[0023] FIG. 11 shows representative powder X-ray diffraction (XRD)
pattern for calcined pure-silica CIT-7 produced in fluoride media
using
3,3'-(butane-1,4-diyl)bis(1,2,4,5-tetramethyl-1H-imidazol-3-ium)
cation. See Example 8.1.
[0024] FIG. 12 shows representative powder X-ray diffraction (XRD)
pattern for calcined aluminosilicate CIT-7 produced in fluoride
media with the
3,3'-(butane-1,4-diyl)bis(1,2,4,5-tetramethyl-1H-imidazol-3-ium)
cation and gel Si/Al=50, as described in Example 8.
[0025] FIGS. 13A and 13B show representative powder X-ray
diffraction (XRD) patterns for as-made CIT-7 (FIG. 13A) and
calcined CIT-7 (FIG. 13B) produced in hydroxide media with the
3,3'-(butane-1,4-diyl)bis(1,2,4,5-tetramethyl-1H-imidazol-3-ium)
cation and gel Si/Al=15, as described in Example 8.1.
[0026] FIG. 14 shows the 3-dimensional ED tomography data used to
solve the structure of CIT-7.
[0027] FIG. 15 shows the Rietveld refinement fit (Rwp=0.077;
Rexp=0.068; RF=0.055). Upper traces: synchrotron data; Middle
traces: calculated data; Lower traces: difference. Upper inset is
magnified 6 times.
[0028] FIG. 16 shows a view along the 10-membered ring channel
system of CIT-7.
[0029] FIG. 17 shows a view along the 8-membered ring channel
system of CIT-7.
[0030] FIG. 18 shows the secondary building units found in
CIT-7.
[0031] FIG. 19 shows an assembly of the CIT-7 framework from
secondary building units. The mtw and the new [4.sup.45.sup.2]
(cse) composite building units assembled to form a repeating
building unit. The connection of the building units forms a chain.
The arrangement of the chain forms a layer with distorted 8-rings.
Connection of the layers forms 10-ring channels that are
intersected with the 8-ring channels.
[0032] FIG. 20 show the isosurface contours of CIT-7
[0033] FIG. 21 shows the .sup.13C CP-MAS NMR spectrum of as-made
CIT-7 (upper) showing the occluded
3,3'-(butane-1,4-diyl)bis(1,2,4,5-tetramethyl-1H-imidazol-3-ium)
cation along with peak assignments and comparison to the liquid
.sup.13C NMR spectrum (lower).
[0034] FIG. 22 shows an Argon isotherm of CIT-7, micropore volume
determined to be 0.19 cm.sup.3/g (t-plot method).
[0035] FIG. 23 shows an .sup.29Si MAS NMR spectrum of calcined pure
silicate CIT-7 (upper) and the deconvolution of .sup.29Si MAS NMR
spectrum of calcined pure silicate CIT-7 (lower).
[0036] FIG. 24 shows an .sup.27Al MAS NMR spectrum of
aluminosilicate CIT-7. Upper is fluoride mediated synthesis with
gel Si/Al=15 and lower is hydroxide mediated synthesis with gel
Si/Al=5. The sample made in hydroxide media is 95% tetrahedral
aluminum and the sample made in fluoride media is 88% tetrahedral
aluminum.
[0037] FIG. 25 shows a UV-VIS spectrum of titanosilicate CIT-7.
[0038] FIG. 26A and FIG. 26B show representative powder X-ray
diffraction (XRD) patterns for calcined IWV, as described in
Example 8.1. FIG. 26A shows a pattern for calcined IWV produced in
hydroxide media at Si/Al=15. FIG. 26B shows a pattern for as-made
(lower) and calcined (upper) IWV produced in fluoride media at gel
Si/Al=50
[0039] FIG. 27 shows a representative powder X-ray diffraction
(XRD) pattern for as-made CIT-8P, as described in Example 9.1.
[0040] FIG. 28 shows a representative powder X-ray diffraction
(XRD) pattern for calcined CIT-8, as described in Example 9.1.
[0041] FIG. 29 shows representative powder X-ray diffraction (XRD)
pattern for calcined HEU made in hydroxide media, as described in
Example 9.1.
[0042] FIG. 30A show a .sup.27Al MAS NMR spectrum for calcined HEU
produced in hydroxide media. The single resonance in this spectrum
is consistent with tetrahedral aluminum, that is aluminum in the
framework. FIG. 30B show a .sup.27Al MAS NMR spectrum for calcined
HEU produced in fluoride media. The majority of the aluminum in
this sample is tetrahedral but there is a small amount of
octahedral aluminum (0 ppm).
[0043] FIG. 31 shows representative powder X-ray diffraction (XRD)
patterns for as-made pure-silica STW (lower) and calcined
pure-silica STW (upper), as described in Example 9.1.
[0044] FIG. 32 shows representative powder X-ray diffraction (XRD)
patterns for as-made STW+layered (lower) and calcined STW (upper),
as described in Example 9.1
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0045] The present invention is directed to crystalline microporous
solids of HEU, RTH, CIT-7, and IWV topologies, and processes and
intermediates used in making such crystalline materials. Such
compositions and methods include the use of organic structure
defining agents including quaternized imidazolium cations and
linked pair of quaternary imidazolium cations.
[0046] The present invention may be understood more readily by
reference to the following description taken in connection with the
accompanying Figures and Examples, all of which form a part of this
disclosure. It is to be understood that this invention is not
limited to the specific products, methods, processes, conditions or
parameters described or shown herein, and that the terminology used
herein is for the purpose of describing particular embodiments by
way of example only and is not intended to be limiting of any
claimed invention. Similarly, unless specifically otherwise stated,
any description as to a possible mechanism or mode of action or
reason for improvement is meant to be illustrative only, and the
invention herein is not to be constrained by the correctness or
incorrectness of any such suggested mechanism or mode of action or
reason for improvement. Throughout this specification, claims, and
drawings, it is recognized that the descriptions refer to
compositions and processes of making and using said compositions.
That is, where the disclosure describes or claims a feature or
embodiment associated with a composition or a method of making or
using a composition, it is appreciated that such a description or
claim is intended to extend these features or embodiment to
embodiments in each of these contexts (i.e., compositions, methods
of making, and methods of using).
Terms
[0047] In the present disclosure the singular forms "a," "an," and
"the" include the plural reference, and reference to a particular
numerical value includes at least that particular value, unless the
context clearly indicates otherwise. Thus, for example, a reference
to "a material" is a reference to at least one of such materials
and equivalents thereof known to those skilled in the art, and so
forth.
[0048] When a value is expressed as an approximation by use of the
descriptor "about," it will be understood that the particular value
forms another embodiment. In general, use of the term "about"
indicates approximations that can vary depending on the desired
properties sought to be obtained by the disclosed subject matter
and is to be interpreted in the specific context in which it is
used, based on its function. The person skilled in the art will be
able to interpret this as a matter of routine. In some cases, the
number of significant figures used for a particular value may be
one non-limiting method of determining the extent of the word
"about." In other cases, the gradations used in a series of values
may be used to determine the intended range available to the term
"about" for each value. Where present, all ranges are inclusive and
combinable. That is, references to values stated in ranges include
every value within that range.
[0049] It is to be appreciated that certain features of the
invention which are, for clarity, described herein in the context
of separate embodiments, may also be provided in combination in a
single embodiment. That is, unless obviously incompatible or
specifically excluded, each individual embodiment is deemed to be
combinable with any other embodiment(s) and such a combination is
considered to be another embodiment. Conversely, various features
of the invention that are, for brevity, described in the context of
a single embodiment, may also be provided separately or in any
sub-combination. Finally, while an embodiment may be described as
part of a series of steps or part of a more general structure, each
said step may also be considered an independent embodiment in
itself, combinable with others.
[0050] The transitional terms "comprising," "consisting essentially
of," and "consisting" are intended to connote their generally in
accepted meanings in the patent vernacular; that is, (i)
"comprising," which is synonymous with "including," "containing,"
or "characterized by," is inclusive or open-ended and does not
exclude additional, unrecited elements or method or process steps;
(ii) "consisting of" excludes any element, step, or ingredient not
specified in the claim; and (iii) "consisting essentially of"
limits the scope of a claim to the specified materials or steps
"and those that do not materially affect the basic and novel
characteristic(s)" of the claimed invention. Embodiments described
in terms of the phrase "comprising" (or its equivalents), also
provide, as embodiments, those which are independently described in
terms of "consisting of" and "consisting essentially of" For those
embodiments provided in terms of "consisting essentially of" the
basic and novel characteristic(s) of a process is the ability to
provide a microporous material having the designated topologies,
and of a product or intermediate, one having the designated
topology.
[0051] When a list is presented, unless stated otherwise, it is to
be understood that each individual element of that list, and every
combination of that list, is a separate embodiment. For example, a
list of embodiments presented as "A, B, or C" is to be interpreted
as including the embodiments, "A," "B," "C," "A or B," "A or C," "B
or C," or "A, B, or C."
[0052] Unless defined otherwise, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. Although
any methods and materials similar or equivalent to those described
herein can also be used in the practice or testing of the present
invention, representative illustrative methods and materials are
described herein.
[0053] Throughout this specification, words are to be afforded
their normal meaning, as would be understood by those skilled in
the relevant art. However, so as to avoid misunderstanding, the
meanings of certain terms will be specifically defined or
clarified.
[0054] The terms "halo" and "halogen" are used in the conventional
sense to refer to a chloro, bromo, fluoro, or iodo substituent.
[0055] "Lower alcohols" or lower alkanes refer to alcohols or
alkanes, respectively, having 1-10 carbons, linear or branched,
preferably I-6 carbon atoms and preferably linear. Methanol,
ethanol, propanol, butanol, pentanol, and hexanol are examples of
lower alcohols. Methane, ethane, propane, butane, pentane, and
hexane are examples of lower alkanes.
[0056] Unless otherwise indicated, the term "isolated" means
physically separated from the other components so as to be free of
solvents or other impurities; additional embodiments include those
where the compound is substantially the only solute in a solvent or
solvent fraction, such a analytically separated in a liquid or gas
chromatography phase.
[0057] "Optional" or "optionally" means that the subsequently
described circumstance may or may not occur, so that the
description includes embodiments where the circumstance occurs and
instances where it does not. For example, the phrase "optionally
substituted" means that a non-hydrogen substituent may or may not
be present on a given atom, and, thus, the description includes
structures wherein a non-hydrogen substituent is present and
structures wherein a non-hydrogen substituent is not present.
Similarly, the phrase "optionally isolated" means that the target
material may or may not be separated from other materials used or
generated in the method, and, thus, the description includes
separate embodiments where the target molecule or other material is
separated and where the target material is not separated, such that
subsequence steps are conducted on isolated or in situ generated
product.
[0058] The terms "separating" or "separated" carries their ordinary
meaning as would be understood by the skilled artisan, insofar as
it connotes separating or isolating the product material from other
starting materials or co-products or side-products (impurities)
associated with the reaction conditions yielding the material. As
such, it infers that the skilled artisan at least recognizes the
existence of the product and takes specific action to separate or
isolate it. Absolute purity is not required, though preferred, as
the material may contain minor amounts of impurities and the
separated or isolated material may contain residual solvent or be
dissolved within a solvent used in the reaction or subsequent
purification of the material.
[0059] As used herein, the term "crystalline microporous solids" or
"crystalline microporous silicate or aluminosilicate solids,"
sometimes referred to as "molecular sieves," are crystalline
structures having very regular pore structures of molecular
dimensions, i.e., under 2 nm. The term "molecular sieve" refers to
the ability of the material to selectively sort molecules based
primarily on a size exclusion process. The maximum size of the
species that can enter the pores of a crystalline microporous solid
is controlled by the dimensions of the channels. These are
conventionally defined by the ring size of the aperture, where, for
example, the term "8-MR" or "8-membered ring" refers to a closed
loop that is typically built from eight tetrahedrally coordinated
silicon (or aluminum) atoms and 8 oxygen atoms. In the present
case, the structures described comprise 8- or 8- and 10-membered
rings or 12-membered rings (designated 8-MR, 8-/10-MR, and 12-MR,
respectively). These rings are not necessarily symmetrical, due to
a variety of effects including strain induced by the bonding
between units that are needed to produce the overall structure, or
coordination of some of the oxygen atoms of the rings to cations
within the structure. The term "silicate" refers to any composition
including silica. It is a general term encompassing, for example,
pure-silica, aluminosilicate, borosilicate, or titanosilicate
structures. The term "zeolite" refers to an aluminosilicate
composition that is a member of this family.
[0060] The present invention is directed to several new crystalline
microporous solids, having 2-dimensional channel systems with 8-MR,
8-/10-MR openings and 12-MR openings, and methods of preparing the
same. One set comprises crystalline material having an RTH topology
generally (including SSZ-50), and especially aluminosilicate
compositions having low Si:Al ratios, and methods for preparing
these types of materials. A second set, described herein as CIT-7,
is a new crystal form, and includes a broad range of compositions
having 2 dimensional channels and 8-/10-MR openings. A third set of
materials comprises solids having HEU topology, having
2-dimensional channels and 8-/10-MR openings, especially
aluminosilicate materials having high Si:Al ratios. A fourth set of
material comprises solids having IWV topologies, having
2-dimensional channels and 12-MR framework, especially those
compositions having high Si:Al ratios. Additional embodiments are
directed to methods of making these new compositions. These new
methods may also be used to prepare compositions having known Si:Al
ratios.
[0061] In some embodiments, the crystalline microporous solids may
be characterized by the dimensions and directions of the rings
(Table 1).
TABLE-US-00001 TABLE 1 Representative dimensions of the
compositions described herein (from IZA) 8-MR 10-MR 8-MR 8-MR 12-MR
12-MR [001].sup.a [001].sup.a [100].sup.a [010] [001].sup.a
[011].sup.a CIT-7 5.1 .times. 2.9 .times. 6.2 .ANG. 5.5 .ANG. HEU
3.6 .times. 3.1 .times. 2.8 .times. (CIT-8) 4.6 .ANG. 7.5 .ANG. 4.7
.ANG. RTH 2.5 .times. 3.8 .times. 5.6 .ANG. 4.1 .ANG. IWV 6.2
.times. 6.2 .times. 6.9 .ANG. 6.9 .ANG. .sup.a[001], [100], [010],
and [011] refer to crystallographic directions. Such directions are
provided for guidance only, and may vary slightly in some
embodiments. It is understood that these ring directions are for
ideal materials. In real materials, small deviations occur.
[0062] The inventive processes may be described, at least in part,
in terms of hydrothermally treating a composition comprising a
silicate source, aluminosilicate source, or metallosilicate source
in the presence of an Organic Structure Directing Agent ("OSDA"),
described herein and selected depending on the nature of the
desired product, under conditions sufficient to form the desired
crystalline product, and optionally recovering and further
processing the crystalline products. These as-synthesized
crystalline materials may contain occluded OSDA within their pore
structures, which can be removed by thermal or oxidative
treatments. One of the many advantages of the OSDAs of the present
invention over phosphorus-containing OSDAs is that they avoid the
inclusion of P atoms or oxides on calcining which inevitably occur
on use of the phosphorus-containing OSDAs. Similarly, the
compositions associated with these processes are also considered
within the scope of the invention.
[0063] Some embodiments include processes (and compositions) for
preparing crystalline microporous solids, each process comprising
hydrothermally treating a composition comprising: [0064] (a) (i) at
least one source of a silicon oxide, germanium oxide, or
combination thereof; and optionally [0065] (ii) at least one source
of aluminum oxide, boron oxide, gallium oxide, hafnium oxide, iron
oxide, tin oxide, titanium oxide, indium oxide, vanadium oxide,
zirconium oxide, or combination or mixture thereof; and [0066] (b)
a linked pair of quaternary imidazolium cations of a structure:
##STR00002##
[0066] under conditions effective to crystallize a crystalline
microporous solid;
[0067] wherein t is 3, 4, 5, or 6, preferably 4 or 5; and
[0068] R is independently methyl or ethyl, preferably methyl or
mainly methyl, and n is independently 1, 2, or 3; said linked pair
of quaternary imidazolium cations having associated fluoride or
hydroxide ions, preferably substantially free of other halide
counterions, i.e., bromide, chloride, or iodide. As used herein,
the term "linked pair of quaternary imidazolium cations" is
intended to connote that two quaternary imidazolium cations are
linked by the carbon linker, and not that the two quaternized
cations are necessarily identical, though this is preferred.
[0069] Subsets of this embodiment include those where (a) comprises
only at least one source of a silicon oxide, germanium oxide, or
combination thereof, preferably only at least one source of a
silicon oxide. Such methods are useful for producing crystalline
silicate microporous solids having an RTH, or CIT-7 topology.
Additional subsets of this embodiment include those where (a)
comprises only at least one source of a silicon oxide and at least
one source of aluminum or titanium oxide. Such methods are useful
for producing crystalline microporous solids, especially
aluminosilicates or titanosilicates having CIT-7, HEU, RTH or IWV
topologies.
[0070] In preferred embodiments, the composition being
hydrothermally treated comprises only at least one source of
silicon oxide or at least one form of silicon oxide and at least
one source of aluminum oxides, for the preparation of crystalline
microporous silicate and aluminosilicate solids, respectively. In
some specific cases, sources of titanium oxide may be substituted
or used in conjunction with the sources of aluminum oxide.
[0071] As described in the Examples below, depending on specific
reaction conditions, particularly temperature and water:Si ratio,
the product crystalline microporous silicate solid may
independently have an RTH or HEU (e.g., designated CIT-8 or CIT-8P)
or IWV or a topology designated as CIT-7.
[0072] As used throughout, the counterions of the organic structure
directing agents are fluoride or hydroxide, and substantially free
of other halide counterions, i.e., bromide, chloride, or iodide. In
this context, the term "substantially free" refers to a condition
where no bromide, chloride, or iodide are added to the composition
or process, and in fact, reasonable efforts are taken to remove
these from the composition or process, e.g., by ion exchange
methods. It does not require absolute absence of these anions, as
for example, as may result from incidental residual bromide,
chloride, or iodide contained within the inorganic materials.
[0073] In other embodiments, it may be desirable to hydrothermally
treat at least one source of a silicon oxide, germanium oxide, or
combination thereof under analogous conditions.
[0074] The dication designation shown in Formula (I) may also be
characterized by the resonance structures shown here, reflecting
the nature of the cationic charge distribution over the imidazolium
cations.
##STR00003##
[0075] In certain preferred embodiments, the linked pair of
quaternary imidazolium cations has a structure:
##STR00004##
where t is 3, 4, 5, or 6; and the associated ions are preferably
hydroxide. When t=3, 4, or 5, in some cases, compositions of the
CIT-8P type morphology can be prepared. When t=3, 4, or 5, in some
cases, the formation of CIT-7 type morphology appears to be
favored, whereas when t=5, in some cases, the formation of the RTH
topology is favored. IWV can be formed when t=4, 5, or 6 (see,
e.g., Tables 9, 9B, 14, and 15 and Example 7.2).
[0076] In some embodiments, the a linked pair of quaternary
imidazolium cations may be described not only with respect to ethyl
and methyl groups, but also in terms of a C/N+ ratio, where the C
represents the number of carbon atoms and N+ represents the number
of quaternized nitrogen atoms associated with each imidazolium
cation. In these embodiments, the C/N+ ratio for each imidazolium
can be independently in the range of from t 6:1 to 10:1, preferably
from 6:1, from 7:1, or from 8:1 to 9:1, more preferably 8:1. For
the purpose of counting carbon atoms, the linking carbon chain is
considered to provide a single carbon atom to each imidazolium
cation. For example, in the embodiment where t is 5, and the linked
pair of quaternary imidazolium cations has associated hydroxide
ions, the linked pair of quaternary imidazolium cations may be
represented by the structure:
##STR00005##
each imidazolium cation would have eight associated carbon atoms (3
ring carbons, 4 methyl carbons, and one linking carbon) and one
charged quaternary nitrogen atom, for a C/N+ ratio of 8:1. Since,
by this definition, the linking carbon chain provides only a single
carbon to each imidazolium cation, this ratio would be independent
of the value oft. (Note that other definitions sometimes used in
the art provide for an accounting of all of the carbons in the
linking chain. In this convention, the values for C/N+ ratio are
correspondingly higher to account for all of the linking carbon
atoms. For example, by this convention, the example above would
have nineteen associated carbon atoms (6 ring carbons, 8 methyl
carbons, and five linking carbons) and two charged quaternary
nitrogen atoms, for a C/N+ ratio of 19:2 or 9.5:1).
[0077] Other embodiments relate to processes for the preparation of
crystalline microporous solids, each process comprising
hydrothermally treating a composition comprising: [0078] (a) (i) at
least one source of silicon oxide and [0079] (ii) at least one
source of aluminum oxide, boron oxide, gallium oxide, hafnium
oxide, iron oxide, tin oxide, titanium oxide, indium oxide,
vanadium oxide, zirconium oxide, or combination or mixture thereof
in the presence of an organic complex comprising [0080] (b) an
imidazolium cation comprising methyl and ethyl groups and having a
C/N+ ratio in a range of from 6:1 to 10:1, preferably from 6:1,
from 7:1, or from 8:1 to about 9:1, or 8:1, such that the
imidazolium has, for example, [0081] (i) 3, 4, or 5 methyl groups
or [0082] (ii) 2, 3, or 4 methyl groups and one ethyl group and
[0083] (c) an associated hydroxide or fluoride anion, preferably
hydroxide and preferably substantially free of other halide
counterions, i.e., bromide, chloride, or iodide; under conditions
effective to crystallize an RTH-, HEU, CIT-7-, or IWV-type
crystalline microporous solid.
[0084] In some preferred embodiments, the processes are used to
prepare crystalline aluminosilicate solids. Such embodiments
include those comprising hydrothermally treating a composition
comprising: [0085] (a) (i) at least one source of a silicon oxide,
germanium oxide, or combination thereof; [0086] (ii) at least one
source of aluminum oxide; and optionally [0087] (iii) at least one
source of boron oxide, gallium oxide, hafnium oxide, iron oxide,
tin oxide, titanium oxide, indium oxide, vanadium oxide, zirconium
oxide, or combination or mixture thereof; and [0088] (b) an
imidazolium cation comprising methyl and ethyl groups and having a
C/N+ ratio in a range of from 6:1 to 10:1, preferably from 6:1,
from 7:1, or 8:1 to 9:1, more preferably 8:1, such that the
imidazolium, for example, has (i) 3, 4, or 5 methyl groups or (ii)
2, 3, or 4 methyl groups and one ethyl group, and (iii) a hydroxide
or fluoride anion, preferably substantially free of other halide
counterions, i.e., bromide, chloride, or iodide;
[0089] under the conditions effective to crystallize an RTH-, HEU-,
CIT-7, or IWV-type crystalline microporous solid, preferably an
aluminosilicate solid (described herein; see Examples 3-9 for
exemplary conditions).
[0090] Again, the separate formation of each of the RTH-, HEU,
CIT-7, or IWV-type crystalline microporous solid can be directed by
the separate choice of temperature, water:Si ratios, and other
parameters, some of which are described in the Examples as specific
embodiments. For example, the RTH topology can be obtained using HF
or hydroxide-mediated conditions, at temperatures ranging from
about 100.degree. C. to about 200.degree. C., preferably from about
150.degree. C. to about 180.degree. C., or more preferably from
about 160.degree. C. to about 175.degree. C. and a water:Si ratio
ranging from about 2:1 to about 20:1, preferably from about 4:1 to
about 10:1 in fluoride mediated syntheses or from about 2:1 to
about 40:1, preferably from about 15:1 to about 20:1 in hydroxide
mediated syntheses. Non-limiting, exemplary conditions are shown,
e.g., in Examples 3, 5 and 7.
[0091] The CIT-7-type topology can be obtained using HF or
hydroxide-mediated conditions, at temperatures ranging from about
150.degree. C. to about 180.degree. C., or preferably from about
160.degree. C. to about 175.degree. C. and at lower water:Si ratios
(e.g., from about 2:1 to about 5:1), with silicates in HF mediated
syntheses, or with aluminosilicates (Si:Al ratios from about 15:1
to about 250:1, preferably about 20:1) in HF- or hydroxide-mediated
syntheses, using OSDAs comprising monoquat imidazolium cations or
preferably those having linked pairs of quaternized imidazolium
cations, where the linking chain length is 3-5 carbons, preferably
about 4 carbons. Non-limiting, exemplary conditions are shown,
e.g., in Examples 3 and 8.
[0092] The HEU topology can be obtained using HF or
hydroxide-mediated conditions, at temperatures ranging from about
100.degree. C. to about 200.degree. C., preferably from about
150.degree. C. to about 180.degree. C., or more preferably from
about 160.degree. C. to about 175.degree. C. and at lower water:Si
ratios (e.g., from about 4:1 to about 7:1) and Si:Al ratios (e.g.,
from about 5:1 to about 50:1, preferably from about 5:1 to about
20:1), using OSDAs having linked pairs of quaternized imidazolium
cations, where the linking chain length is 3-5 carbons.
Non-limiting, exemplary conditions are shown, e.g., in Examples 3
and 9.
[0093] While the pure silicate-containing crystalline microporous
solids and the HEU and CIT-7 topologies appear to require, or at
least favor, the use of the linked pair of quaternary imidazolium
cations, other crystalline materials appear to favor the use of
mono-quaternary imidazolium cations having the parameters described
above. Exemplary imidazolium cations include those aromatic
structures described by a resonance form that is:
##STR00006##
[0094] Typical sources of silicon oxide for the reaction mixtures
include alkoxides, hydroxides, or oxides of silicon, or combination
thereof. Exemplary compounds also include silicates (including
sodium silicate), silica hydrogel, silicic acid, fumed silica,
colloidal silica, tetra-alkyl orthosilicates, and silica
hydroxides.
[0095] Typical sources of aluminum oxide for the reaction mixture
include aluminates, alumina, aluminum colloids, aluminum alkoxides,
aluminum oxide coated on silica sol, hydrated alumina gels such as
Al(OH).sub.3 and a sodium aluminate. Sources of aluminum oxide may
also comprises an alkoxide, hydroxide, or oxide of aluminum, or
combination thereof. Additionally, the sources of alumina may also
comprise other ligands as well, for example acetylacetonate,
carboxylates, and oxalates; such compounds are well known as useful
in hydrothermal or sol-gel syntheses.
[0096] Sources of boron oxide, gallium oxide, hafnium oxide, iron
oxide, tin oxide, titanium oxide, indium oxide, vanadium oxide,
and/or zirconium oxide can be added in forms corresponding to their
aluminum and silicon counterparts.
[0097] In other embodiments, a source inorganic reagent may also
provide a source of aluminum. In some cases, the source inorganic
also provides a source of silicate. The source zeolite in its
dealuminated form may also be used as a source of silicate, with
additional silicon added using, for example, the conventional
sources listed above. Use of a source zeolite reagent as a source
of alumina for the present process is more completely described in
U.S. Pat. No. 4,503,024, the disclosure of which is incorporated
herein by reference.
[0098] In those cases where the source of silicon or aluminum is an
alkoxide, their respective empirical formulae are preferably
Si(OR).sub.4 and Al(OR).sub.3, where R is an alkyl group of 1-6
carbon atoms, including methyl, ethyl, n-propyl, isopropyl,
n-butyl, sec-butyl, tert-butyl, n-pentyl, isopentyl, hexyl Some of
these compounds, especially Al(OR).sub.3, form complicated bridging
structures in solution, even before hydrolysis. In some
embodiments, the silicon alkoxide is tetraethyl orthosilicate
(TEOS) and the aluminum alkoxide is Al(i-OPr).sub.3.
[0099] In the processes directed to preparing the aluminosilicate
zeolites, some embodiments provide that the ratio of Si:Al in the
composition is in a range of from about 5:1 to about 250:1.
Additional embodiments include those where the ratio is in a range
bounded at the lower end by a value of about 5:1, 10:1, 15:1, 20:1,
or 25:1 and bounded at the upper end by a value of about 250:1,
100:1, 50:1, 30:1, 25:1, 20:1, 15:1, or about 10:1. In those
embodiments where some of the Al are substituted by B, Ga, Hf, Fe,
Sn, Ti, In, V, or Zr, these ratios refer to the ratio of Si:(Al+B,
Ga, Hf, Fe, Sn, Ti, In, V, and/or Zr). In some cases, these lead to
crystalline compositions having Si:Al ratios which are lower than
the forming compositions (see, e.g., Table 5). In other cases, the
crystalline compositions may have Si:Al ratios which are higher
than the forming compositions (see, e.g., Table 15).
[0100] The compositions of these processes may also include
mineralizing media including aqueous HF or aqueous hydroxide. Where
the media comprise aqueous hydroxide, the source of the hydroxide
may be an alkali metal hydroxide and/or an alkaline earth metal
hydroxide, such as the hydroxide of sodium, potassium, lithium,
cesium, rubidium, barium, calcium, and magnesium, is used in the
reaction mixture. The OSDA may be used to provide hydroxide ion,
thereby reducing or eliminating the alkali metal hydroxide quantity
required. The alkali metal cation or alkaline earth cation may be
part of the as-synthesized crystalline oxide material, in order to
balance valence electron charges therein.
[0101] In some embodiments, the ratio of imidazolium cation:Si is
in a range of from about 0.05:1 to about 1:1. In the embodiments
where the OSDA is a linked pair of quaternary imidazolium cations,
each imidazolium moiety is considered individually. Certain
embodiments provide preferred ratios, depending on the nature of
the mineralizing system; i.e., whether it is hydroxide mediated or
fluoride mediated. In the fluoride mediated systems, certain
preferred embodiments include those where the range of the
imidazolium cation:Si ratio is in a range of from about 0.2:1 to
about 1:1, more preferably about 0.5:1. In hydroxide mediated
systems, the preferred imidazolium cation:Si is typically in a
range of from about 0.05:1 to about 1:1, preferably about
0.2:1.
[0102] In other embodiments, the ratio of water:Si is in a range of
from about 2:1 to about 20:1, preferably in a range of from about
4:1 to about 10:1. Additional embodiments include those where the
range is bounded at the lower end by a value of about 2:1, 3:1,
4:1, 5:1, 6:1, 7:1, 8:1, 9:1, 10:1, 12:1, 14:1, 16:1, 18:1, or 20:1
and bounded at the upper end by a value of about 20:1, 18:1, 16:1,
14:1, 12:1, or about 10:1. As with some of the other parameters,
the preferred water:Si ratio may depend on the inorganic system,
whether it is hydroxide mediated or fluoride mediated. In the
fluoride mediated systems, a preferred water:Si range is from about
2:1 to 20:1 and most preferably 4:1 to 10:1. In hydroxide mediated
system, a preferred water:Si range is from about 2:1 to 40:1 and
most preferably about 15-20:1.
[0103] In processing the crystalline microporous solids, the
reaction mixture is maintained at an elevated temperature until the
crystals of the desired product form are formed. The hydrothermal
crystallization is usually conducted under autogenous pressure, at
a temperature between 100.degree. C. to about 200.degree. C.,
preferably about 140.degree. C. to about 180.degree. C. or from
about 160.degree. C. to about 180.degree. C., for a time effective
for crystallizing the desired crystalline microporous solid. The
crystallization period is typically greater than I day and
preferably from about 1 day to about 40 days, or from about 3 days
to about 20 days. Preferably, the zeolite is prepared using mild
stirring or agitation.
[0104] During the hydrothermal crystallization step, the
crystalline microporous solids can be allowed to nucleate
spontaneously from the reaction mixture. The use of product
crystals as seed material can be advantageous in decreasing the
time necessary for complete crystallization to occur. In addition,
seeding can lead to an increased purity of the product obtained by
promoting the nucleation and/or formation of the desired
crystalline microporous solid over any undesired phases. When used
as seeds, such seed crystals are added in an amount between 0.1 and
5% or between 0.1 and 10% of the weight of silicate-source used in
the reaction mixture.
[0105] Once the crystals have formed, the solid product can be
separated from the reaction mixture by standard mechanical
separation techniques such as filtration or centrifugation. The
crystals can be water-washed and then dried, e.g., at 90.degree. C.
to 150.degree. C. for from 8 to 24 hours, to obtain the
as-synthesized crystalline microporous solids. The drying step can
be performed at atmospheric pressure or under vacuum.
[0106] In various embodiments, the processes described herein
produce or are capable of producing compositionally "clean"
crystalline microporous materials. That is, in various embodiments,
the crystalline microporous materials described herein are at least
75%, 80%, 85%, 90%, 95%, or 98% by weight of the nominal topology.
In some embodiments, the crystalline microporous materials exhibit
XRD patterns where other crystalline topologies are
undetectable.
[0107] Similarly, in various embodiments the as-formed, calcined,
or doped microporous materials that are free from phosphorus atoms
or oxides.
[0108] The hydrothermal processes provide as-synthesized
crystalline materials having the desired topology which contain the
imidazolium OSDAs used to prepare the materials occluded in the
pore structures, and these compositions are considered within the
scope of the present invention.
[0109] The crystalline microporous solids can be used
as-synthesized, but preferably are thermally treated (calcined), in
part to remove the occluded organic OSDAs. For example, in certain
embodiments, the isolated as-synthesized crystalline intermediate
are treated under oxidative (e.g., air or oxygen) or inert
atmosphere at at least one temperature in a range of from about
350.degree. C. to about 850.degree. C. or about 1000.degree. C.
When a strongly oxidizing atmosphere is uses (e.g., ozone), the
temperature is generally lower, for example, in a range from about
25.degree. C. to about 200.degree. C. In some embodiments, the
as-synthesized intermediates are calcined first under an inert
atmosphere to pyrolyze the organic occlusions, then calcined in air
(optionally including added O.sub.2 or ozone) to remove the
deposited carbon. In other embodiments, the as-synthesized zeolites
are calcined directly under oxidizing conditions. Representative
ramp rates are provided in the Examples. Note that the calcining or
pyrolysis reactions result in the formation of crystalline
microporous materials that are free from P atoms or oxides, a
distinguishing feature over materials made from some other
methods.
[0110] It is also often desirable to remove any alkali metal cation
by ion exchange and replace it with hydrogen, ammonium, or any
desired metal ion. The zeolite can be leached with chelating
agents, e.g., EDTA or dilute acid solutions, to increase the silica
to alumina mole ratio. The crystalline microporous solid can also
be steamed; steaming helps stabilize the crystalline lattice to
attack from acids. Alternatively, or additionally, the calcined
materials may be treated with aqueous ammonium salts (e.g.,
NH.sub.4NO.sub.3) to remove any residual inorganic cations in the
pores of the crystalline solid.
[0111] The crystalline microporous solids can be used in intimate
combination with hydrogenating components, such as tungsten,
vanadium molybdenum, rhenium, nickel cobalt, chromium, manganese,
or a noble metal, such as palladium or platinum, for those
applications in which a hydrogenation-dehydrogenation function is
desired.
[0112] Metals may also be introduced into the crystalline
microporous solid by replacing some of the cations in the
crystalline microporous solid with metal cations via standard ion
exchange techniques. (see, for example, U.S. Pat. No. 3,140,249
issued Jul. 7, 1964 to Plank et al.; U.S. Pat. No. 3,140,251 issued
Jul. 7, 1964 to Plank et al.; and U.S. Pat. No. 3,140,253 issued
Jul. 7, 1964 to Plank et al.). Typical replacing cations can
include metal cations, e.g., rare earth, Group 1, Group 2 and Group
8 metals, as well as their mixtures. Cations of metals such as rare
earth, Mn, Ca, Mg, Zn, Cd, Pt, Pd, Ni, Co, Ti, Al, Sn, and Fe are
particularly preferred.
[0113] Following contact with the salt solution of the desired
replacing cation, the crystalline microporous solid is typically
washed with water and dried at temperatures ranging from 65.degree.
C. to about 200.degree. C. After washing, the crystalline
microporous solid can be calcined in air or inert gas at
temperatures ranging from about 25.degree. C. to about 200.degree.
C. or from about 200.degree. C. to about 850.degree. C. or about
1000.degree. C., as described above and depending on the nature of
the calcining atmosphere, for periods of time ranging from 1 to 48
hours or more, to produce a catalytically active product especially
useful in hydrocarbon conversion processes. Regardless of the
cations present in the synthesized form of the crystalline
microporous solid, the spatial arrangement of the atoms which form
the basic crystal lattice of the crystalline solid remains
essentially unchanged.
[0114] The crystalline microporous solids may also be treated under
conditions so as to incorporate at least one type of transition
metal or transition metal oxide catalyst into the pore structure,
for example by vapor or chemical deposition or precipitation. As
used herein, the term "transition metal" refers to any element in
the d-block of the periodic table, which includes groups 3 to 12 on
the periodic table. In actual practice, the f-block lanthanide and
actinide series are also considered transition metals and are
called "inner transition metals. Scandium, yttrium, titanium,
zirconium, vanadium, manganese, chromium, molybdenum, tungsten,
iron, ruthenium, osmium, cobalt, rhodium, iridium, nickel,
palladium, platinum, copper, silver, gold, or mixtures thereof are
preferred.
[0115] The as-synthesized or calcined crystalline microporous
solids can be formed into a wide variety of physical shapes.
Generally speaking, the zeolite can be in the form of a powder, a
granule, or a molded product, such as extrudate. In cases where the
catalyst is molded, such as by extrusion with an organic binder,
these crystalline solids can be extruded before drying, or, dried
or partially dried and then extruded. The crystalline microporous
solids can be composited with other materials resistant to the
temperatures and other conditions employed in organic conversion
processes. Such matrix materials include active and inactive
materials and synthetic or naturally occurring crystalline solids,
including zeolites, as well as inorganic materials such as clays,
silica and metal oxides.
[0116] To this point, the embodiments have been described mainly in
terms of processes to prepare the crystalline microporous solids,
but the compositions used in these processes are also considered
within the scope of the present invention(s). For the sake of
completeness, some of these are repeated here, but this partial
listing should not be interpreted as abandoning those embodiments
not specifically listed.
[0117] Certain embodiments include those compositions, especially
useful for preparing crystalline microporous silicate solids,
comprising:
[0118] (a) at least one source of a silicon oxide (optionally
including germanium oxide, or combination thereof);
[0119] (b) a linked pair of quaternary imidazolium cations of a
structure:
##STR00007##
[0120] wherein t is 3, 4, 5, or 6, preferably 4 or 5; and
[0121] R is independently methyl or ethyl, and n is independently
1, 2, or 3; said linked pair of quaternary imidazolium cations
having associated fluoride or hydroxide ions, and as more broadly
described as above; and
[0122] (c) optionally at least one crystal of a compositionally
consistent crystalline HEU, RTH, CIT-7, or IWV solid. In this
regard, the compositions preferably, but not necessarily, contain
crystals of any one of the compositionally consistent crystalline
HEU, RTH, or CIT-7 solid. In some of these embodiments, a portion
of the linked pair of quaternary imidazolium cations is occluded in
the pores of the crystals.
[0123] Certain additional embodiments include those compositions,
especially useful for preparing other crystalline microporous
solids, said compositions comprising:
[0124] (a) at least one source of a silicon oxide (germanium oxide,
or combination thereof);
[0125] (b) at least one source of aluminum oxide, boron oxide,
gallium oxide, hafnium oxide, iron oxide, tin oxide, titanium
oxide, indium oxide, vanadium oxide, zirconium oxide, or
combination or mixture thereof; and [0126] (c) an imidazolium
cation comprising methyl and ethyl groups and having a C/N+ ratio
in a range of from 6:1 to 10:1, preferably from 6:1, from 7:1, or
from 8:1 to 9:1 or 8:1, such that the imidazolium has, for example,
[0127] (i) 3, 4, or 5 methyl groups or [0128] (ii) 2, 3, or 4
methyl groups and one ethyl group and [0129] (c) a hydroxide or
fluoride anion, preferably substantially free of other halide
counterions, i.e., bromide, chloride, or iodide; and [0130] (d)
optionally a compositionally consistent crystalline HEU, RTH,
CIT-7, or IWV solid. Again, in this regard, a preferred embodiment
is a composition useful for creating aluminosilicate
products--i.e., where at least one source of source of aluminum
oxide is present. Also, and again, the compositions preferably, but
not necessarily, contain crystals of any one of the compositionally
consistent crystalline HEU, RTH, CIT-7, or IWV solid. In some of
these embodiments, a portion of the imidazolium cation is occluded
in the pores of the crystals.
[0131] Additional embodiments include those described above, as
well as embodiments where the composition does independently
contain a crystalline HEU, RTH, CIT-7, or IWV composition, and
particularly a compositionally consistent crystalline HEU, RTH,
CIT-7, or IWV composition. As used herein, the term
"compositionally consistent crystalline HEU, RTH, CIT-7, or IWV
composition" describes a crystalline composition that has the same
topology of the named framework, and preferably is a silicate
version of that topology or the crystalline composition contains
the same types of oxides as do the sources of oxides, albeit not
necessarily in the same atomic or molecular proportions--e.g.,
derived from added seed crystals, hydrothermally formed crystals,
or both. Here, the term "substantially free" refers to the absence
of added materials having different topologies than the present
RTH, HEU, or CIT-7 crystals, again which may be present either as
added seed crystals or as formed during hydrothermal treatment of
the composition.
[0132] The imidazolium cations used in the compositions, especially
useful for preparing these crystalline materials, may be described
by a resonance form that is:
##STR00008##
[0133] The sources of silicon oxide, aluminum oxides, boron oxide,
gallium oxide, hafnium oxide, iron oxide, tin oxide, titanium
oxide, indium oxide, vanadium oxide, and/or zirconium oxide used in
these compositions are as described above in terms of the
processes.
[0134] Similarly, the specific chemistries associated with the HF
and hydroxide mediated processes (including ratios of imidazolium
cation to Si, water to Si, and Si to Al) and described above are
also considered within the description of the corresponding
compositions.
[0135] In certain separate embodiments, the compositions are
solutions or gels, as understood by those of ordinary skill in this
art.
[0136] Also considered within the scope of the present invention(s)
are those crystalline compositions comprising a crystalline
microporous solid, prepared by any of the processes described
herein, either as-synthesized, calcined, or otherwise modified.
Some of these embodiments include those crystalline silicate
compositions having an RTH structure, an HEU structure, a CIT-7
structure, or an IWV structure and having pores at least some of
which are occluded with a linked pair of quaternary imidazolium
cations of a structure:
##STR00009##
including those OSDAs as more fully described above, and those
crystalline compositions having pores, at least some of which are
occluded with an organic complex comprising (a) an imidazolium
cation comprising methyl and ethyl groups and having a C/N+ ratio
in a range of from 6:1 to 10:1, preferably from 6:1, from 7:1, or
from 8:1 to 9:1, more preferably 8:1.
[0137] As described below, specific embodiments include those
crystalline compositions having an RTH structure, an HEU structure,
a CIT-7 structure, or an IWV structure where the occluded linked
pair of imidazolium cations ("diquat") or mono-quaternized
imidazolium cations according ("monoquats") can be described by a
resonance form that is:
##STR00010##
The specific nature of the occluded linked pair of imidazolium
cations ("diquat") or mono-quaternized imidazolium cations
according ("monoquats") in each case reflects that OSDA used in in
the preparation of the specific crystalline microporous
material.
[0138] The crystalline compositions containing the occluded linked
pair of quaternary imidazolium cations or quaternized imidazolium
cation include those compositions where the ratio of Si:Al is in a
range of from about 5:1 to about .infin.:1 (i.e., pure silicate).
Additional independent embodiments include those crystalline
compositions with the occluded OSDA where the ratio of Si:Al is in
a range from about 4:1 to 5:1, from about 5:1 to about 7.3:1, from
about 7.3:1 to about 10:1, from about 10:1 to about 12.3:1, from
about 12.3:1 to about 15:1, from about 15:1 to about 17.3:1, from
about 17.3:1 to about 20:1, from about 20:1 to about 25:1, from
about 25:1 to about 30:1, from about 30:1 to about 50:1, from about
50:1 to about 75:1, from about 75:1 to about 100:1, from about
100:1, from about 100:1 to about 250:1, from about 250:1 to about
.infin.:1, or a combination of two or more of these ranges. Note
that a Si:Al ratio of infinity (.infin.) corresponds to a silicate
composition substantially free of Al.
[0139] Still further embodiments include those calcined, doped, or
otherwise modified crystalline compositions having RTH, HEU, CIT-7,
or IWV structures prepared by these inventive methods, and absent
the occluded linked pair of quaternary imidazolium cations or
imidazolium cations, that exhibit Si:Al ratios over one or more of
these ranges.
[0140] Additional embodiments include those crystalline microporous
solids having an RTH structure, absent the occluded linked pair of
quaternary imidazolium cations or imidazolium cations (i.e., where
these organic materials have been removed) comprising (a) silicon
oxide and (b) aluminum oxide, boron oxide, gallium oxide, hafnium
oxide, iron oxide, tin oxide, titanium oxide, indium oxide,
vanadium oxide, zirconium oxide, or combination thereof, wherein
the molar ratio of (a) to (b) is in a range of from about 5 to
about 20, from about 5 to about 15, from about 5 to about 10, or
from about 10 to about 15. In certain of these embodiments, the
frameworks of these crystalline aluminosilicate zeolites contain
oxides of silicon and at least aluminum. In certain of these
embodiments, the solids exhibit an XRD diffraction pattern the same
as or consistent with that shown in FIG. 1, FIG. 2, or FIG. 9A/B,
reflective of the pore sizes comparable to or the same as those
described in Table 1. In other embodiments, the crystalline RTH
solid exhibits a single peak in the .sup.27Al MAS spectrum, in some
cases having a chemical shift 54 ppm downfield of a peak
corresponding to aqueous Al(NO.sub.3).sub.3 as shown in FIG. 6. In
other embodiments, these microporous solids contain the doped
metals or transition metals or oxides described herein. Additional
characteristics of these materials may be found in the
Examples.
[0141] Still further embodiments include those crystalline
microporous solids having an HEU structure, absent the occluded
linked pair of quaternary imidazolium cations or imidazolium
cations (i.e., where these organic materials have been removed)
comprising (a) silicon oxide and (b) aluminum oxide and optionally
boron oxide, gallium oxide, hafnium oxide, iron oxide, tin oxide,
titanium oxide, indium oxide, vanadium oxide, zirconium oxide, or
combination thereof, wherein the molar ratio of (a) to (b) is in a
range of from about 5 to about 7.3, from 7.3 to about 10, from
about 10 to about 12.3, from about 12.3 to about 15, from about 15
to about 17.3, from about 17.3 to about 20, or a combination of two
or more of these ranges. In certain of these embodiments, the
frameworks of these crystalline aluminosilicate zeolites contain
only alumina and silica. In certain embodiments, these crystalline
microporous silicate or aluminosilicate solids having an HEU
structure were prepared by either topotactic condensation from a
layered precursor material, denoted CIT-8P, or by direct synthesis,
as described herein.
[0142] In certain other of these embodiments, the crystalline
microporous solid having an HEU structure exhibit an XRD
diffraction pattern the same as or consistent with that shown in
FIG. 27, FIG. 28, or FIG. 29, reflective of the pore sizes
comparable to or the same as those described in Table 1. In other
embodiments, these crystalline microporous solids contain the doped
metals or transition metals or oxides described herein. In some
embodiments, the crystalline microporous solid having an HEU
structure exhibits a .sup.27Al MAS NMR spectrum that is the same as
or consistent with the spectra of that shown in FIG. 30A or FIG.
30B. Additional characteristics of these materials may be found in
the Examples.
[0143] Additional embodiments include those crystalline microporous
solids having a topology as described as CIT-7, absent the occluded
linked pair of quaternary imidazolium cations or imidazolium
cations (i.e., where these organic materials have been removed)
comprising either a pure silicate structure, or an structure
comprising (a) silicon oxide and (b) aluminum oxide, boron oxide,
gallium oxide, hafnium oxide, iron oxide, tin oxide, titanium
oxide, indium oxide, vanadium oxide, zirconium oxide, or
combination thereof, preferably aluminosilicates. The framework
structure has been determined from a combination of rotation
electron diffraction and synchrotron X-ray powder diffraction data,
and may be defined in the following terms. The structure has 10
crystallographically unique tetrahedral atoms (T-atoms) in the unit
cell, and can be described as an ordered arrangement of the
[4.sup.25.sup.46.sup.2] mtw building unit and a previously
unreported [4.sup.45.sup.2] building unit. The framework contains a
2-dimensional pore system that is bounded by 10 T-atom rings
(10-ring, 5.1 .ANG. *6.2 .ANG. opening) that are connected with
oval 8-rings (2.9 .ANG. *5.5 .ANG. opening) through medium-sized
cavities (7.9 .ANG.) at the channel intersections.
[0144] In certain of these embodiments, the frameworks of these
crystalline microporous CIT-7 solids contain oxides of silicon and
at least aluminum. In other embodiments, these crystalline zeolites
contain oxides of silicon and titanium. In certain of these
embodiments, the solids exhibit an XRD diffraction pattern the same
as or consistent with that shown in FIG. 11, FIG. 12, or FIG.
13A/B, reflective of the pore sizes comparable to or the same as
those described in Table 1. In other embodiments, the crystalline
silica CIT-7 solid exhibits a plurality of peak in the .sup.29Si
MAS spectrum, in some cases having chemical shifts of about 115.59,
about 115.19, 111.2, 109.58, 109.27, 108.81, and about 106.735 ppm
downfield of a peak corresponding to tetramethylsilane as shown in
FIG. 23. Aluminosilicate versions of CIT-7 may exhibit .sup.27Al
MAS spectrum corresponding to FIG. 24. Other additional
characteristics of these materials may be found in the Examples. In
other embodiments, the crystalline silicate CIT-7 solid can be
characterized by the crystallographic parameters substantially as
described in Table 11. In still other embodiments, these
crystalline microporous CIT-7 solids contain the doped metals or
transition metals or oxides described herein.
[0145] Additional embodiments include those crystalline microporous
solids having an IWV topology, absent the occluded linked pair of
quaternary imidazolium cations or imidazolium cation (i.e., where
these organic materials have been removed) comprising either a pure
silicate structure, or an structure comprising (a) silicon oxide
and (b) aluminum oxide, boron oxide, gallium oxide, hafnium oxide,
iron oxide, tin oxide, titanium oxide, indium oxide, vanadium
oxide, zirconium oxide, or combination thereof, preferably
aluminosilicates. Some embodiments provide that these structures
exhibit a characteristic XRD diffraction pattern as shown in FIG.
26A or FIG. 26B. In some other embodiments, these IWV frameworks
are pure silicates or aluminosilicates, having a Si:Al ratio of
about 7.3:1, or in a range of from about 4:1 to about 5:1, from
about 5:1 to about 10:1, from about 10:1 to about 15:1, from about
15:1 to about 20:1, from about 20:1 to about 25:1, from about 25:1
to about 30:1, from about 30:1 to about 50:1, from about 50:1 to
about 100:1, from about 100:1 to about 250:1, from about 250:1 to
infinity, or any combination of these ranges. Note that a Si:Al
ratio of infinity (.infin.) corresponds to a silicate composition
substantially free of Al.
[0146] The various crystalline structures described herein are
conveniently described in terms of their characteristic XRD
diffraction patterns. Certain embodiments include those structures
exhibiting any one of the XRD patterns shown in any one of the
Figures of this specification. Tables 2A and 2B provide tabulations
of major peaks within each spectrum, and separate embodiments
include those structures having at least the five major peaks of
each spectrum, and optionally additional peaks, preferably in order
of decreasing relative heights (intensities).
TABLE-US-00002 TABLE 2A Representative XRD data for structures
described in this specification Calcined pure Calcined Calcined
Calcined topotactic silica RTH SiAl-RTH Si-CIT-7 HEU (CIT-8)
2-.theta. Relative 2-.theta. Relative 2-.theta. Relative 2-.theta.
Relative (deg) Height (deg) Height (deg) Height (deg) Height 8.56
100.0 8.56 94.7 7.43 100.0 10.02 100 9.03 89.0 9.06 100.0 8.26
100.0 11.28 32.9 10.09 28.7 10.14 53.8 9.62 13.6 13.12 18.5 10.18
41.0 17.70 10.1 10.08 18.0 13.42 8.4 12.42 2.9 18.76 28.0 10.48
19.9 17.38 12.5 17.71 7.5 19.52 15.3 14.83 9.5 22.51 20.6 18.79
18.4 19.83 9.2 18.42 7.8 22.76 26.6 19.61 11.3 23.13 11.4 22.96 7.6
26.44 7.8 25.09 7.6 25.00 17.0 23.55 6.7 28.29 7.0 30.75 2.9 25.49
13.2 25.02 8.5 30.35 9.5
TABLE-US-00003 TABLE 2B Representative XRD data for structures
described in this specification As-made layered Hydroxide Calcined
IWV Calcined HEU (CIT-8P) HEU (Si/Al = 15) STW 2-.theta. Relative
2-.theta. Relative 2-.theta. Relative 2-.theta. Relative (deg)
Height (deg) Height (deg) Height (deg) Height 7.17 100.0 9.64 18.2
6.02 13.7 9.05 42.6 11.41 11.9 9.95 100.0 6.40 100.0 10.44 100.0
14.15 26.6 11.22 49.9 7.09 16.8 12.40 29.7 16.13 13.2 13.09 27.3
7.90 12.8 14.73 27.6 18.12 19.4 17.35 28.8 7.99 61.0 17.35 32.0
19.84 32.9 22.46 40.8 9.49 9.3 22.76 31.2 21.93 10.1 22.72 46.8
12.85 9.7 22.93 34.7 22.71 9.8 26.28 20.6 19.04 14.9 23.52 24.0
24.40 22.4 30.25 24.4 21.07 10.7 25.82 24.9 25.19 22.1 32.05 15.2
26.71 12.2 26.01 31.7
[0147] As described herein, the variation in the scattering angle
(two theta) measurements, due to instrument error and to
differences between individual samples, is estimated at .+-.0.15
degrees. The X-ray diffraction patterns shown in this application
are considered representative of "as-synthesized" or "as-made" and
calcined crystalline structures. Minor variations in the
diffraction pattern can result from variations in the, e.g.,
silica-to-alumina mole ratio of the particular sample due to
changes in lattice constants. In addition, sufficiently small
crystals will affect the shape and intensity of peaks, leading to
significant peak broadening. Calcination can also result in changes
in the intensities of the peaks as compared to patterns of the
"as-made" material, as well as minor shifts in the diffraction
pattern. The crystalline solids produced by exchanging the metal or
other cations present in the solids with various other cations
(NH.sub.4.sup.+ and then calcining to produce H.sup.+) yields
essentially the same diffraction pattern, although again, there may
be minor shifts in the interplanar spacing and variations in the
relative intensities of the peaks. Notwithstanding these minor
perturbations, the basic crystal lattice remains unchanged by these
treatments. Accordingly, the skilled artisan would expect that a
description that structures having XRD patterns with peaks within
such small variances shown in Tables 2A and 2B would still be
considered within the scope of this invention.
[0148] The calcined crystalline microporous solids, calcined or
doped or treated with the catalysts described herein may also be
used as catalysts for a variety of chemical reactions, including
hydrocracking hydrocarbons, dewaxing hydrocarbon feedstocks,
isomerizing hydrocarbons including olefins, producing higher
molecular weight hydrocarbons from lower molecular weight
hydrocarbons, converting lower alcohols and other oxygenated
hydrocarbons to produce liquid products including olefins, reducing
the content of oxides of nitrogen contained in a gas stream in the
presence of oxygen, and separating nitrogen from a
nitrogen-containing gas mixture. In each case, the processes
include contacting the respective feedstock with the catalyst under
conditions sufficient to affect the transformation. Such
transformations are known to those of ordinary skill in the
art.
[0149] In various embodiments, the crystalline microporous solids
mediate or catalyze an array of chemical transformation. As
follows, each of the crystalline solid materials will have utility
in at least each of the following applications, though it is
believed that those having 8-MR structures (i.e., RTH, HEU, and
CIT-7) will be especially useful in converting lower alcohols and
other oxygenated hydrocarbons to produce liquid products including
olefins, reducing the content of oxides of nitrogen contained in a
gas stream in the presence of oxygen, and separating nitrogen from
a nitrogen-containing gas mixture. Those compositions having 10-MR
(i.e., HEU, CIT-7) or 12-MR (IWV) will be useful in hydrocarbon
processing.
[0150] Some embodiments provide processes for converting
hydrocarbons, each process comprising contacting a
hydrocarbonaceous feed at hydrocarbon converting conditions with a
catalyst comprising a crystalline microporous solid of this
invention. The crystalline material may be predominantly in the
hydrogen form, partially acidic or substantially free of acidity,
depending on the process.
[0151] Other embodiments provide hydrocracking processes, each
process comprising contacting a hydrocarbon feedstock under
hydrocracking conditions with a catalyst comprising a crystalline
microporous solid of this invention, preferably predominantly in
the hydrogen form.
[0152] Still other embodiments provide processes for dewaxing
hydrocarbon feedstocks, each process comprising contacting a
hydrocarbon feedstock under dewaxing conditions with a catalyst
comprising a crystalline microporous solid of this invention,
preferably predominantly in the hydrogen form.
[0153] Yet other embodiments provide processes for improving the
viscosity index of a dewaxed product of waxy hydrocarbon feeds,
each process comprising contacting the waxy hydrocarbon feed under
isomerization dewaxing conditions with a catalyst comprising a
crystalline microporous solid of this invention, preferably
predominantly in the hydrogen form.
[0154] Additional embodiments include those process for producing a
C20+ lube oil from a C20+ olefin feed, each process comprising
isomerizing said olefin feed under isomerization conditions over a
catalyst comprising at least one transition metal catalyst and a
crystalline microporous solid of this invention. The crystalline
microporous solid may be predominantly in the hydrogen form.
[0155] Also included in the present invention are processes for
isomerization dewaxing a raffinate, each process comprising
contacting said raffinate in the presence of added hydrogen with a
catalyst comprising at least one transition metal and a crystalline
microporous solid of this invention. The raffinate may be bright
stock, and the zeolite may be predominantly in the hydrogen
form.
[0156] Also included in this invention is a process for increasing
the octane of a hydrocarbon feedstock to produce a product having
an increased aromatics content, each process comprising contacting
a hydrocarbonaceous feedstock which comprises normal and slightly
branched hydrocarbons having a boiling range above about 40.degree.
C. and less than about 200.degree. C., under aromatic conversion
conditions with a catalyst comprising a crystalline microporous
solid of this invention made substantially free of acidity by
neutralizing said zeolite with a basic metal. Also provided in this
invention is such a process wherein the crystalline microporous
solid contains a transition metal component.
[0157] Also provided by the present invention are catalytic
cracking processes, each process comprising contacting a
hydrocarbon feedstock in a reaction zone under catalytic cracking
conditions in the absence of added hydrogen with a catalyst
comprising a crystalline microporous solid of this invention,
preferably predominantly in the hydrogen form. Also included in
this invention is such a catalytic cracking process wherein the
catalyst additionally comprises a large pore crystalline cracking
component.
[0158] This invention further provides isomerization processes for
isomerizing C4 to C7 hydrocarbons, each process comprising
contacting a feed having normal and slightly branched C4 to C
hydrocarbons under isomerizing conditions with a catalyst
comprising a crystalline microporous solid of this invention,
preferably predominantly in the hydrogen form. The crystalline
microporous solid may be impregnated with at least one transition
metal, preferably platinum. The catalyst may be calcined in a
steam/air mixture at an elevated temperature after impregnation of
the transition metal.
[0159] Also provided by the present invention are processes for
alkylating an aromatic hydrocarbon, each process comprising
contacting under alkylation conditions at least a molar excess of
an aromatic hydrocarbon with a C2 to C20 olefin under at least
partial liquid phase conditions and in the presence of a catalyst
comprising a crystalline microporous solid of this invention,
preferably predominantly in the hydrogen form. The olefin may be a
C2 to C4 olefin, and the aromatic hydrocarbon and olefin may be
present in a molar ratio of about 4:1 to about 20:1, respectively.
The aromatic hydrocarbon may be selected from the group consisting
of benzene, toluene, ethylbenzene, xylene, or mixtures thereof.
[0160] Further provided in accordance with this invention are
processes for transalkylating an aromatic hydrocarbon, each of
which process comprises contacting under transalkylating conditions
an aromatic hydrocarbon with a polyalkyl aromatic hydrocarbon under
at least partial liquid phase conditions and in the presence of a
catalyst comprising a crystalline microporous solid of this
invention, preferably predominantly in the hydrogen form. The
aromatic hydrocarbon and the polyalkyl aromatic hydrocarbon may be
present in a molar ratio of from about 1:1 to about 25:1,
respectively. The aromatic hydrocarbon may be selected from the
group consisting of benzene, toluene, ethylbenzene, xylene, or
mixtures thereof, and the polyalkyl aromatic hydrocarbon may be a
dialkylbenzene.
[0161] Further provided by this invention are processes to convert
paraffins to aromatics, each of which process comprises contacting
paraffins under conditions which cause paraffins to convert to
aromatics with a catalyst comprising a crystalline microporous
solid of this invention, said catalyst comprising gallium, zinc, or
a compound of gallium or zinc.
[0162] In accordance with this invention there is also provided
processes for isomerizing olefins, each process comprising
contacting said olefin under conditions which cause isomerization
of the olefin with a catalyst comprising a crystalline microporous
solid of this invention.
[0163] Further provided in accordance with this invention are
processes for isomerizing an isomerization feed, each process
comprising an aromatic C8 stream of xylene isomers or mixtures of
xylene isomers and ethylbenzene, wherein a more nearly equilibrium
ratio of ortho-, meta- and para-xylenes is obtained, said process
comprising contacting said feed under isomerization conditions with
a catalyst comprising the zeolite of this invention.
[0164] The present invention further provides processes for
oligomerizing olefins, each process comprising contacting an olefin
feed under oligomerization conditions with a catalyst comprising a
crystalline microporous solid of this invention.
[0165] This invention also provides processes for converting lower
alcohols and other oxygenated hydrocarbons, each process comprising
contacting said lower alcohol (for example, methanol, ethanol, or
propanol) or other oxygenated hydrocarbon with a catalyst
comprising a crystalline microporous solid of this invention under
conditions to produce liquid products. Compositions having the RTH
topology are expected to be especially useful in this regard (see,
e.g., Example 6).
[0166] Also provided by the present invention are processes for
reducing oxides of nitrogen contained in a gas stream in the
presence of oxygen wherein each process comprises contacting the
gas stream with a crystalline microporous solid of this invention.
The a crystalline microporous solid may contain a metal or metal
ions (such as cobalt, copper or mixtures thereof) capable of
catalyzing the reduction of the oxides of nitrogen, and may be
conducted in the presence of a stoichiometric excess of oxygen. In
a preferred embodiment, the gas stream is the exhaust stream of an
internal combustion engine.
[0167] Additional transformations considered within the scope of
the present invention mediated by the crystalline materials of the
present invention, but at least for those crystalline microporous
solids of HEU, CIT-7, and IWV topologies, are those described in
Table 13.
[0168] Specific conditions for each of these transformations are
known to those of ordinary skill in the art. Exemplary conditions
for such reactions/transformations may also be found in
WO/1999/008961, which is incorporated by reference herein in its
entirety for all purposes.
[0169] Depending upon the type of reaction which is catalyzed, the
microporous solid may be predominantly in the hydrogen form,
partially acidic or substantially free of acidity. As used herein,
"predominantly in the hydrogen form" means that, after calcination,
at least 80% of the cation sites are occupied by hydrogen ions
and/or rare earth ions.
[0170] The following listing of embodiments is intended to
complement, rather than displace or supersede, the previous
descriptions.
[0171] Embodiment 1. A process comprising hydrothermally treating a
composition comprising:
[0172] (a) (i) at least one source of a silicon oxide, germanium
oxide, or combination thereof; and optionally [0173] (ii) at least
one source of aluminum oxide, boron oxide, gallium oxide, hafnium
oxide, iron oxide, tin oxide, titanium oxide, indium oxide,
vanadium oxide, zirconium oxide, or combination or mixture thereof;
and
[0174] (b) a linked pair of quaternary imidazolium cations of a
structure:
##STR00011##
under conditions effective to crystallize a crystalline microporous
solid;
[0175] wherein t is 3, 4, 5, or 6, preferably 4 or 5; and
[0176] R is independently methyl or ethyl, preferably methyl, and n
is independently 1, 2, or 3;
[0177] said linked pair of quaternary imidazolium cations having
associated fluoride or hydroxide ions, preferably substantially
free of other halide counterions, i.e., bromide, chloride, or
iodide. Subsets of this embodiment include those where (a)
comprises only at least one source of a silicon oxide, germanium
oxide, or combination thereof, preferably only at least one source
of a silicon oxide. Such methods are useful for producing
crystalline silicate microporous solids having an RTH, HEU, CIT-7,
or IWV topology. Additional subsets of this Embodiment include
those where (a) comprises only at least one source of a silicon
oxide and at least one source of aluminum oxide. Such methods are
useful for producing at least crystalline aluminosilicate
microporous solids having a CIT-7 or IWV topology.
[0178] Embodiment 2. The process of Embodiment 1, wherein the
composition being hydrothermally treated comprises only (i) at
least one source of silicon oxide or (ii) at least one form of
silicon oxide and at least one source of aluminum oxide, for the
preparation of crystalline microporous silicate and aluminosilicate
solids, respectively.
[0179] Embodiment 3. The process of Embodiment 1 or 2, wherein the
linked pair of quaternary imidazolium cations has a structure:
##STR00012##
where t is 3, 4, or 5. Embodiment 4. The process of any one of
Embodiment 1 to 3, wherein the linked pair of quaternary
imidazolium cations has a structure:
##STR00013##
[0180] said linked pair of quaternary imidazolium cations,
preferably having associated hydroxide ions.
[0181] Embodiment 5. A process comprising hydrothermally treating a
composition comprising: [0182] (a) (i) at least one source of
silicon oxide and optionally [0183] (ii) at least one source of
aluminum oxide, boron oxide, gallium oxide, hafnium oxide, iron
oxide, tin oxide, titanium oxide, indium oxide, vanadium oxide,
zirconium oxide, or combination or mixture thereof; [0184] in the
presence of an organic complex comprising [0185] (b) an imidazolium
cation comprising methyl and ethyl groups and having a C/N+ ratio
in a range of from about 6:1 to 10:1, preferably from 6:1, from
7:1, or from 8:1 to 9:1, more preferably 8:1, such that the
imidazolium has, for example, [0186] (i) 3, 4, or 5 methyl groups
or [0187] (ii) 2, 3, or 4 methyl groups and one ethyl group and
[0188] (c) a hydroxide or fluoride anion, preferably substantially
free of other halide counterions, i.e., bromide, chloride, or
iodide; [0189] under conditions effective to crystallize a
microporous solid. Processes for preparing silicates and
aluminosilicates are considered within the scope of preferred
embodiments. The crystalline microporous silicate or
aluminosilicate solid may be one of an RTH, HEU, CIT-7 or IWV
topology.
[0190] Embodiment 6. The process of Embodiment 5, comprising
hydrothermally treating a composition comprising
[0191] (a) (i) at least one source of a silicon oxide, germanium
oxide, or combination thereof; [0192] (ii) at least one source of
aluminum oxide; and optionally [0193] (iii) at least one source of
boron oxide, gallium oxide, hafnium oxide, iron oxide, tin oxide,
titanium oxide, indium oxide, vanadium oxide, zirconium oxide, or
combination or mixture thereof; and
[0194] (b) an imidazolium cation having (i) 3, 4, or 5 methyl
groups or (ii) 2, 3, or 4 methyl groups and one ethyl group, and
(iii) a hydroxide or fluoride anion, preferably substantially free
of other halide counterions, i.e., bromide, chloride, or
iodide;
[0195] under conditions effective to crystallize a microporous
aluminosilicate solid. The crystalline microporous aluminosilicate
solid may be one of an RTH, HEU, CIT-7, or IWV topology.
[0196] Embodiment 7. The process of Embodiment 5 or 6, wherein the
imidazolium cation is described by a resonance form that is:
##STR00014##
[0197] Embodiment 8. The process of any one of Embodiments 1 to 7,
wherein the source of silicon oxide comprises an alkoxide,
hydroxide, or oxide of silicon, or combination thereof. Exemplary
compounds also include silicates, silica hydrogel, silicic acid,
fumed silica, colloidal silica, tetra-alkyl orthosilicates, and
silica hydroxides.
[0198] Embodiment 9. The process of any one of Embodiments 2 to 8,
wherein the source of aluminum oxide comprises an alkoxide,
hydroxide, or oxide of aluminum, or combination thereof.
Additionally, the sources of alumina may also include other ligands
as well, for example acetylacetonate, carboxylates, and oxalates;
such compounds are well known as useful in hydrothermal or sol-gel
syntheses.
[0199] Embodiment 10. The process of any one of Embodiments 2 to 9,
wherein the source of boron oxide, gallium oxide, hafnium oxide,
iron oxide, tin oxide, titanium oxide, indium oxide, vanadium
oxide, zirconium oxide, or combination or mixture thereof comprises
an alkoxide, hydroxide, oxide, or combination thereof of the
corresponding metal.
[0200] Embodiment 11. The process of any one of claims 1 or 3 to
10, wherein the crystalline microporous solid independently
exhibits an RTH, HEU, CIT-7, or IWV topology.
[0201] Embodiment 12. The process of any one of Embodiments 1 to
11, wherein the at least one source of silicon oxide comprise a
silicon alkoxide, a silica, a sodium silicate, or a combination
thereof.
[0202] Embodiment 13. The process of any one of Embodiments 2 to
12, wherein the at least one source of aluminum is an aluminum
alkoxide, an aluminate (e.g., oxide, hydroxide, or mixed
oxide/hydroxide), a sodium aluminate an aluminum siloxide, or a
combination thereof.
[0203] Embodiment 14. The process of Embodiment 12, wherein the
silicon alkoxide is of the formula Si(OR).sub.4, where R is an
alkyl group of 1-6 carbon atoms.
[0204] Embodiment 15. The process of Embodiment 13, wherein the
aluminum alkoxide is of the formula Al(OR).sub.3, where R is an
alkyl group of 1-6 carbon atoms.
[0205] Embodiment 16. The process of any one of Embodiments 2 to
15, wherein the ratio of Si:Al in the composition is in a range of
from about 5:1 to about 250:1. Subset Embodiments include those
wherein the Si:Al ratios ranges from about 4:1 to about 5:1, from
about 5:1 to about 10:1, from about 10:1 to about 15:1, from about
15:1 to about 20:1, from about 20:1 to about 25:1, from about 25:1
to about 30:1, from about 30:1 to about 50:1, from about 50:1 to
about 100:1, from about 100:1 to about 250:1, from about 250:1 to
infinity, or a combination of two or more of these ranges.
[0206] Embodiment 17. The process of any one of Embodiments 1 to
16, wherein the composition further comprises aqueous HF.
[0207] Embodiment 18. The process of any one of Embodiments 1 to
16, wherein the composition further comprises aqueous hydroxide,
for example sodium hydroxide, potassium hydroxide, lithium
hydroxide, cesium hydroxide, rubidium hydroxide, barium hydroxide,
calcium hydroxide, or magnesium hydroxide.
[0208] Embodiment 19. The process of Embodiment 17, wherein the
ratio of imidazolium cation:Si is in a range of from about 0.0.2:1
to about 1:1, preferably about 0.5:1.
[0209] Embodiment 20. The process of Embodiment 18, wherein the
ratio of imidazolium cation:Si is in a range of from about 0.05 to
about 1:1, preferably about 0.2:1.
[0210] Embodiment 21. The process of Embodiment 17 or 19, wherein
the ratio of water:Si is in a range of from about 2:1 to about
20:1, preferably in a range of from about 4:1 to about 10:1.
[0211] Embodiment 22. The process of Embodiments 18 or 20, wherein
the ratio of water:Si is in a range of from about 2:1 to about
40:1, preferably in a range of from about 15-20:1.
[0212] Embodiment 23. The process of any one of Embodiments 1 to
22, wherein the hydrothermally treating is done at a temperature in
a range of from about 100.degree. C. to about 200.degree. C.,
preferably about 140.degree. C. to about 180.degree. or from about
160.degree. C. to about 180.degree. C., for a time effective for
crystallizing the crystalline microporous solid.
[0213] Embodiment 24. The process of any one of Embodiments 1 to
23, further comprising isolating a crystalline microporous
solid.
[0214] Embodiment 25. The process of Embodiment 24, wherein the
crystalline microporous solid contains a portion of the imidazolium
cation or linked pair of quaternary imidazolium cations used in its
preparation.
[0215] Embodiment 26. The process of Embodiment 20 or 23, further
comprising calcining the crystalline microporous solid at a
temperature in a range of from about 25.degree. C. to about
850.degree. C. under oxidative (e.g., air, oxygen, or ozone) or
inert atmosphere. When a strongly oxidizing atmosphere is uses
(e.g., ozone), the temperature is generally in a range from about
25.degree. C. to about 200.degree. C. Otherwise, the calcining is
done at at least one temperature in at least one temperature range
of from about 350.degree. C. to about 450.degree. C., from about
450.degree. C. to about 550.degree. C., from about 550.degree. C.
to about 650.degree. C., from about 650.degree. C. to about
750.degree. C., from about 750.degree. C. to about 850.degree.
C.
[0216] Embodiment 27. The process of Embodiment 26, further
comprising treating the calcined material with an aqueous ammonium
salt.
[0217] Embodiment 28. The process of Embodiment 26, further
comprising treating at least some pores of the microporous solid
with at least one type of transition metal or transition metal
oxide
[0218] Embodiment 29. A composition comprising:
[0219] (a) at least one source of a silicon oxide, germanium oxide,
or combination thereof;
[0220] (b) a linked pair of quaternary imidazolium cations of a
structure:
##STR00015##
[0221] wherein t is 3, 4, 5, or 6; and
[0222] R is independently methyl or ethyl, and n is independently
1, 2, or 3;
said linked pair of quaternary imidazolium cations having
associated fluoride or hydroxide ions; and
[0223] (c) optionally a compositionally consistent crystalline
microporous silicate solid. In some of these embodiments, a portion
of the linked pair of imidazolium cations is occluded in the pores
of the crystals
Preferably, the linked pair of quaternary imidazolium cations has a
structure of:
##STR00016##
and said linked pair of quaternary imidazolium cations having
associated hydroxide ions.
[0224] Embodiment 30. The composition of claim 29, further
comprising at least one source of aluminum oxide, boron oxide,
gallium oxide, hafnium oxide, iron oxide, tin oxide, titanium
oxide, indium oxide, vanadium oxide, zirconium oxide, or
combination or mixture thereof. A subset of this embodiment
includes that where the at least one source of aluminum oxide is
necessarily present.
[0225] Embodiment 31. A composition comprising: [0226] (a) at least
one source of a silicon oxide, germanium oxide, or combination
thereof and optionally [0227] (b) a source of aluminum oxide; and
[0228] (c) an imidazolium cation comprising methyl and ethyl groups
and having a C/N+ ratio in a range of from about 6:1 to 10:1,
preferably from 6:1, from 7:1, or from 8:1 to 9:1, more preferably
8:1, such that the imidazolium cation has, for example, [0229] (i)
3, 4, or 5 methyl groups or [0230] (ii) 2, 3, or 4 methyl groups
and one ethyl group and [0231] (c) a hydroxide or fluoride anion,
preferably substantially free of other halide counterions, i.e.,
bromide, chloride, or iodide; and [0232] (d) optionally a
compositionally consistent crystalline microporous aluminosilicate
solid. This compositionally crystalline microporous aluminosilicate
solid may independently have an RTH, HEU, or CIT-17 topology, the
specific nature of which depends on the target crystalline
microporous composition. In some of these embodiments, a portion of
the imidazolium cation is occluded in the pores of the crystals.
Additional subsets of this Embodiment include those where only at
least one source of a silicon oxide is present and those where at
least one source of silicon oxide and at least one source of
aluminum oxide are present.
[0233] Embodiment 32. The composition of Embodiment 31, further
comprising a source of boron oxide, gallium oxide, hafnium oxide,
iron oxide, tin oxide, titanium oxide, indium oxide, vanadium
oxide, zirconium oxide, or combination or mixture thereof.
[0234] Embodiment 33. The composition of Embodiment 31 or 32,
wherein the imidazolium cation is described by a resonance form
that is:
##STR00017##
[0235] Embodiment 34. The composition of any one of Embodiments 29
to 33, wherein the source of silicon oxide comprises an alkoxide,
hydroxide, or oxide of silicon, or combination thereof.
[0236] Embodiment 35. The composition of any one of Embodiments 30
to 34 wherein the source of aluminum oxide comprises an alkoxide,
hydroxide, or oxide of aluminum, an aluminum siloxide, or
combination thereof.
[0237] Embodiment 36. The composition of any one of Embodiments 29
to 35, wherein the source of silicon comprise a silicon alkoxide
having an empirical formula of Si(OR).sub.4, where R is an alkyl
group of 1-6 carbon atoms.
[0238] Embodiment 37. The composition of any one of Embodiments 30
to 36, wherein the source of aluminum comprise an aluminum alkoxide
having an empirical formula of Al(OR).sub.3, where R is an alkyl
group of 1-6 carbon atoms.
[0239] Embodiment 38. The composition of any one of Embodiments 29
to 37, wherein the composition further comprises aqueous HF.
[0240] Embodiment 39. The composition of any one of Embodiments 29
to 37, wherein the composition further comprises aqueous
hydroxide.
[0241] Embodiment 40. The composition of Embodiment 38, wherein the
ratio of imidazolium cation:Si is in a range of from about 0.2:1 to
about 1:1, preferably about 0.5:1.
[0242] Embodiment 41. The composition of Embodiment 39, wherein the
ratio of imidazolium cation:Si is in a range of from about 0.05 to
about 1:1, preferably about 0.2:1.
[0243] Embodiment 42. The composition of Embodiment 38 or 40,
wherein the ratio of water:Si is in a range of from about 2:1 to
about 20:1, preferably 4:1 to 10:1.
[0244] Embodiment 43. The process of Embodiments 39 or 41, wherein
the ratio of water:Si is in a range of from about 2:1 to about
40:1, preferably in a range of from about 15:1 to 20:1
[0245] Embodiment 44. The composition of any one of Embodiments 30
to 43 wherein the ratio of Si:Al in the composition is in a range
of from about 5:1 to about 250:1.
[0246] Embodiment 45. The composition of any one of Embodiments 29
to 44, which is a gel.
[0247] Embodiment 46. The composition of any one of Embodiments 29
to 45, further independently comprising a crystalline microporous
solid having RTH, HEU, CIT-7 or IWV topology.
[0248] Embodiment 47. The composition Embodiment 46, wherein the
microporous solid having RTH, HEU, CIT-7, or IWV topology has a
Si:Al ratio in a range of at least 5. Note that an Si:Al ratio of
infinity (Go) corresponds to a silicate composition substantially
free of Al.
[0249] Embodiment 48. The composition of Embodiment 46 or 47, that
is substantially free of other crystalline materials.
[0250] Embodiment 49. A crystalline microporous solid prepared by
the process of any one of Embodiments 1 to 28. A subset of this
Embodiment includes those calcined crystalline microporous solid,
prepared by a process of any one of Embodiments 26 to 28. Another
subset of this Embodiment includes those compositions, whether
prepared by or independent of one of these processes, where the
ratio of Si:Al is in a range of from about 4:1 to 5:1, from about
5:1 to about 7.3:1, from about 7.3:1 to about 10:1, from about 10:1
to about 12.3:1, from about 12.3:1 to about 15:1, from about 15:1
to about 17.3:1, from about 17.3:1 to about 20:1, from about 20:1
to about 25:1, from about 25:1 to about 50:1, from about 50:1 to
about 75:1, from about 75:1 to about 100:1, from about 100:1 to
about 250:1, from about 250:1 to .infin.:1, or a combination of two
or more of these ranges, whether as-synthesized, calcined, doped,
or otherwise modified.
[0251] Embodiment 50. The crystalline solid of Embodiment 49, the
crystalline microporous solid independently having an RTH, HEU,
CIT-7 or IWV topology.
[0252] Embodiment 51. A crystalline microporous solid of claim 49
or 50 having pores at least some of which are occluded with a
linked pair of quaternary imidazolium cations of a structure:
##STR00018##
[0253] wherein t is 3, 4, 5, or 6, preferably 4 or 5;
[0254] R is independently methyl or ethyl, and n is independently
1, 2, or 3; or any of the more specific linked pair of quaternary
imidazolium cations described herein. Depending on the specific
conditions used to prepare the solid, the crystalline solid has an
RTH, HEU, CIT-7, or IWV topology, as described herein.
[0255] Embodiment 52. A crystalline microporous solid of claim 49
or 50 having pores, at least some of which are occluded with an
organic complex comprising (a) an imidazolium cation comprising
methyl and ethyl groups and having a C/N+ ratio in a range of from
about 6:1 to 10:1, preferably from 6:1, from 7:1, or from 8:1 to
9:1, more preferably 8:1, and where the crystalline microporous
solid has an RTH, HEU, CIT-7, or IWV topology, depending on the
specific conditions used to prepare the solid as described
herein.
[0256] Embodiment 53. The crystalline microporous solid of
Embodiment 51 or 52, wherein the occluded imidazolium cation or
linked pair of quaternary imidazolium cations is described by a
resonance form that is:
##STR00019##
[0257] Embodiment 54. The crystalline microporous solid of any one
of Embodiments 51 to 53, wherein the crystalline solid is a
microporous silicate solid.
[0258] Embodiment 55. The crystalline microporous solid of any one
of Embodiments 51 or 54, wherein the crystalline solid is a
microporous aluminosilicate solid having a ratio of Si:Al in a
range of from about 5:1 to about 250:1. Subsets of this Embodiments
include those where the range is from about 4:1 to about 5:1, from
about 5:1 to about 10:1, from about 10:1 to about 15:1, from about
15:1 to about 20:1, from about 20:1 to about 25:1, from about 25:1
to about 30:1, from about 30:1 to about 50:1, from about 50:1 to
about 100:1, from about 100:1 to about 250:1, from about 250:1 to
infinity, or a combination of two or more of these ranges.
[0259] Embodiment 56. A crystalline microporous solid having an RTH
structure comprising (a) silicon oxide, germanium oxide, or
combination thereof and (b) aluminum oxide, boron oxide, gallium
oxide, hafnium oxide, iron oxide, tin oxide, titanium oxide, indium
oxide, vanadium oxide, or zirconium oxide, wherein the molar ratio
of (a) to (b) is less than 20, preferably in a range of from about
5 to about 10, from about 10 to about 15, from about 15 to less
than 20, or a combination of two or more of these ranges, more
preferably about 15. One subset of this embodiment is one where the
crystalline microporous solid is an aluminosilicate, where the
ratio of (a) to (b) refers to the ratio of Si to Al.
[0260] Embodiment 57. A calcined crystalline microporous solid
having an RTH structure comprising (a) silicon oxide, germanium
oxide, or combination thereof and (b) aluminum oxide, boron oxide,
gallium oxide, hafnium oxide, iron oxide, tin oxide, titanium
oxide, indium oxide, vanadium oxide, or zirconium oxide wherein the
molar ratio of (a) to (b) is in a range of from about 5 to about
10, from about 10 to about 15, from about 15 to less than 20, or a
combination of two or more of these ranges, more preferably about
15. One subset of this embodiment is one where the crystalline
microporous solid is an aluminosilicate.
[0261] Embodiment 58. An as-synthesized or calcined crystalline
microporous solid having an HEU framework topology comprising (a)
silicon oxide, germanium oxide, or combination thereof and (b)
aluminum oxide, boron oxide, gallium oxide, hafnium oxide, iron
oxide, tin oxide, titanium oxide, indium oxide, vanadium oxide,
zirconium oxide, or combination thereof, wherein the molar ratio of
(a) to (b) is in a range of from about 4 to about 5, from about 5
to about 7.3, from about 7.3 to about 10, from about 10 to about
12.3, from about 12.3 to about 15, from about 15 to about 17.3,
from about 17.3 to about 20, or a combination of two or more of
these ranges. One subset of this embodiment is one where the
crystalline microporous solid is an aluminosilicate, where the
ratio of (a) to (b) refers to the ratio of Si to Al.
[0262] Embodiment 59. A calcined crystalline microporous solid
comprising (a) silicon oxide, germanium oxide, or combination
thereof and optionally (b) aluminum oxide, boron oxide, gallium
oxide, hafnium oxide, iron oxide, tin oxide, titanium oxide, indium
oxide, vanadium oxide, zirconium oxide, or combination thereof,
having 8-MR and 10-MR pore structures and at least one of the
following characteristics:
[0263] (a) the solid exhibits an .sup.29Si MAS spectrum having a
plurality of chemical shifts of about 115.59, about 115.19, 111.2,
109.58, 109.27, 108.81, and about 106.735 ppm downfield of a peak
corresponding to and external standard of tetramethylsilane; or
[0264] (c) the solid exhibits an XRD diffraction pattern the same
as or consistent with those shown in FIG. 11, FIG. 12, or FIG.
13A/B. Subsets of this embodiment include those where the
crystalline microporous solid is a silicate, aluminosilicate, or a
titanosilicate.
[0265] Embodiment 60. A calcined crystalline microporous solid
comprising (a) silicon oxide, germanium oxide, or combination
thereof and optionally (b) aluminum oxide, boron oxide, gallium
oxide, hafnium oxide, iron oxide, tin oxide, titanium oxide, indium
oxide, vanadium oxide, zirconium oxide, or combination thereof,
having cse and mtw building blocks (as shown in FIG. 18 or FIG.
19). Subsets of this embodiment include those where the crystalline
microporous solid is a silicate, aluminosilicate, or a
titanosilicate.
[0266] Embodiment 61. A calcined microporous solid having a
framework substantially as described in Table 11, or an
aluminosilicate or titanosilicate version thereof.
[0267] Embodiment 62. A calcined microporous solid having an IWV
framework and exhibiting an XRD diffraction pattern the same as or
consistent with those shown in FIG. 26A or FIG. 26B.
[0268] Embodiment 63. The calcined microporous solid of Embodiment
62, having an Si:Al ratio in a range of from about 4:1 to about
5:1, from about 5:1 to about 10:1, from about 10:1 to about 15:1,
from about 15:1 to about 20:1, from about 20:1 to about 25:1, from
about 25:1 to about 30:1, from about 30:1 to about 50:1, from about
50:1 to about 100:1, from about 100:1 to about 250:1, from about
250:1 to infinity, or a combination of two or more of these ranges.
Note that an Si:Al ratio of infinity (Go) corresponds to a silicate
composition substantially free of Al.
[0269] Embodiment 64. The calcined compositions of any one of
Embodiments 56 to 61, wherein the calcined composition is
predominantly in the hydrogen form.
[0270] Embodiment 65. A crystalline microporous composition
comprising (a) silicon oxide, germanium oxide, or combination
thereof and (b) aluminum oxide, boron oxide, gallium oxide, hafnium
oxide, iron oxide, tin oxide, titanium oxide, indium oxide,
vanadium oxide, zirconium oxide, or combination thereof, and
exhibiting a powder X-ray diffraction pattern of any one of FIG. 2,
FIG. 9A or B, FIG. 10, FIG. 11, FIG. 12, FIG. 13A/B, FIG. 26A or B,
FIG. 27, FIG. 28, FIG. 29, FIG. 31, or FIG. 32.
[0271] Embodiment 66. A crystalline microporous composition
comprising (a) silicon oxide, germanium oxide, or combination
thereof and (b) aluminum oxide, boron oxide, gallium oxide, hafnium
oxide, iron oxide, tin oxide, titanium oxide, indium oxide,
vanadium oxide, zirconium oxide, or combination thereof, and having
at least the five major peaks, and optionally additional peaks,
preferably in order of decreasing relative intensities, in the
powder X-ray diffraction pattern, substantially as provided in
Tables 2A or 2B.
[0272] Embodiment 67. A process comprising carbonylating DME with
CO at low temperatures, reducing NOx with methane, cracking,
dehydrogenating, converting paraffins to aromatics, MTO,
isomerizing xylenes, disproportionating toluene, alkylating
aromatic hydrocarbons, oligomerizing alkenes, aminating lower
alcohols (including methanol), separating and sorbing lower alkanes
(e.g., C3-C6 alkanes, hydrocracking a hydrocarbon, dewaxing a
hydrocarbon feedstock, isomerizing an olefin, producing a higher
molecular weight hydrocarbon from lower molecular weight
hydrocarbon, reforming a hydrocarbon, converting a lower alcohol or
other oxygenated hydrocarbon to produce an olefin products,
reducing the content of an oxide of nitrogen contained in a gas
stream in the presence of oxygen, or separating nitrogen from a
nitrogen-containing gas mixture by contacting the respective
feedstock with the crystalline microporous solid of any one of
Embodiments 49 or 56 to 65 under conditions sufficient to affect
the named transformation.
[0273] Embodiment 68. A method comprising contacting methanol with
a composition of any one of claims Embodiments 49 or 56 to 65 under
conditions sufficient to convert the methanol to at least one type
of olefin.
EXAMPLES
[0274] The following Examples are provided to illustrate some of
the concepts described within this disclosure. While each Example
is considered to provide specific individual embodiments of
composition, methods of preparation and use, none of the Examples
should be considered to limit the more general embodiments
described herein.
[0275] In the following examples, efforts have been made to ensure
accuracy with respect to numbers used (e.g. amounts, temperature,
etc.) but some experimental error and deviation should be accounted
for. Unless indicated otherwise, temperature is in degrees Celsius,
pressure is at or near atmospheric.
Example 1. Materials and Methods
[0276] Unless otherwise noted all reagents were purchased from
Sigma-Aldrich and were used as received. Hydroxide ion exchanges
were performed using Supelco Dowex Monosphere 550A UPW hydroxide
exchange resin with an exchange capacity of 1.1 meq/mL. Titrations
were performed using a Mettler-Toledo DL22 autotitrator using 0.01
M HCl as the titrant. All liquid NMR spectra were recorded with a
400 MHz Varian Spectrometer.
[0277] The .sup.13C CP-MAS NMR spectra were recorded using a Bruker
Avance 200 MHz spectrometer with a 7 mm rotor at a spinning rate of
4 kHz and were conducted in a 4.7 T magnetic field, corresponding
to Larmor frequencies of 200 MHz and 50.29 MHz for .sup.1H and
.sup.13C respectively. The .sup.13C spectra are referenced to
adamantane as a secondary external standard relative to
tetramethylsilane. .sup.29Si and .sup.19F NMR were performed using
a Bruker DSX-500 spectrometer (11.7 T) and a Bruker 4 mm MAS probe.
The spectral frequencies were 500.2 MHz, 99.4 MHz, and 470.7 MHz
for .sup.1H, and .sup.19F nuclei, respectively, and spectra were
referenced to external standards as follows: tetramethylsilane
(TMS) for .sup.1H and .sup.29Si, and CFCl.sub.3 for .sup.19F. The
.sup.27Al MAS NMR were recorded using a Bruker AM 300 MHz
spectrometer with a 4 mm rotor at a spinning rate of 8 kHz, and
were conducted in a 7.0 T magnetic field corresponding to a Larmor
frequency of 78.172 MHz. The .sup.27Al spectra are referenced to
1.1 M Al(NO.sub.3).sub.3 as an external standard.
[0278] Thermogravimetric analysis measurements were performed with
a Netzsch STA 449C Jupiter. Samples were heated in air to
900.degree. C. at a rate of 1.degree. C./min. All Argon adsorption
isotherms were performed at 87.45 K using a Quantachrome Autosorb
iQ and were conducted using a quasi-equilibrium, volumetric
technique. All powder X-ray diffraction (PXRD) characterization was
conducted on a Rigaku MiniFlex II with Cu K.sub..alpha. radiation.
Scanning electron micrograph (SEM) images were acquired on a ZEISS
1550 VP FESEM, equipped with in-lens SE. EDS spectra were acquired
with an Oxford X-Max SDD X-ray Energy Dispersive Spectrometer
system.
[0279] Diffuse reflectance UV-visible (DRUV) spectra (for CIT-7)
were recorded using a Cary 3G spectrophotometer equipped with a
diffuse reflectance cell; zeolite samples were calcined prior to
data collection. Three-dimensional electron diffraction data were
collected on 2 crystals of CIT-7 using the rotation electron
diffraction (RED) technique of Zhang (D. Zhang, P. Oleynikov, S.
Hovmoller and X. Zou, Z. Kristallogr., 2010, 225, 94-102) and Wan
(W. Wan, J. Sun, J. Su, S. Hovmoller and X. Zou, J. Appl. Cryst.,
2013, 46, 1863-1873). The RED software was installed on a JEOL 2010
microscope operating at 200 kV, and data were collected over a tilt
range of .+-.55.degree. with a tilt step of 0.50.degree. for the
first set and 0.35.degree. for the second set, the exposure time is
3 seconds per tilt step.
Example 2. Synthesis of Imidazolium Cations
Example 2.1
[0280] Pentamethylimidazolium hydroxide was synthesized as shown in
in the following Scheme.
##STR00020##
[0281] Pentamethylimidazolium was synthesized by dissolving
1,2,4,5-tetramethylimidazole (TCI Chemicals) in methanol and then
cooling in a dry ice bath. A three-fold molar excess of iodomethane
(Aldrich) was then slowly added (Caution: Highly exothermic
reaction!) and the mixture was then slowly warmed to room
temperature and stirred for one day. The solvent and excess
iodomethane were then removed using rotary evaporation (Caution:
Highly toxic vapors present, use appropriate precautions) and the
product was recrystallized from acetone and washed with ether. The
structure was verified using .sup.1H and .sup.13C NMR (D.sub.2O,
methanol added as internal standard) and the product was converted
from the iodide to the hydroxide form using hydroxide exchange
resin in water and the product was titrated using a Mettler-Toledo
DL22 autotitrator using 0.01 M HCl as the titrant. .sup.1H-NMR (500
MHz, D.sub.2O): .delta. 3.60 (s, 6H), 2.54 (s, 3H), 2.20 (s, 6H).
NMR (125 MHz, D.sub.2O): .delta. 7.99, 9.76, 31.58, 125.42,
142.21.
Example 2.2. Syntheses of Other Organic Structure Directing Agents
(OSDAs)
[0282] Reaction Type 1:
[0283] The parent imidazole was dissolved in methanol and then
cooled in a dry ice/acetone bath. Then a three-fold molar excess of
methyl iodide was slowly added. (Caution: These reactions can be
highly exothermic, use appropriate precautions.) The mixture was
then allowed to slowly warm to room temperature and finally
refluxed overnight. After cooling the solvent and excess methyl
iodide were removed using rotary evaporation (Caution: Highly toxic
vapors present, use appropriate precautions), and the product was
recrystallized from acetone and washed with ether.
[0284] Reaction Type 2:
[0285] The parent imidazole was dissolved in chloroform and then a
two-fold molar excess of potassium carbonate was added. The mixture
was cooled in a dry ice/acetone bath and then a four-fold molar
excess of methyl iodide was slowly added. (Caution: These reactions
can be highly exothermic, use appropriate precautions.) The mixture
was then allowed to slowly warm to room temperature and finally
refluxed overnight. After cooling to room temperature the potassium
carbonate was filtered off and the solids were rinsed with extra
chloroform to recover all the product. Then the solvent and excess
methyl iodide were removed using rotary evaporation (Caution:
Highly toxic vapors present, use appropriate precautions), and the
product was recrystallized from acetone and washed with ether.
[0286] In both types of reactions the structure was verified using
.sup.13C NMR in D.sub.2O with methanol added as an internal
standard. The products were then converted from iodide to hydroxide
form using hydroxide exchange resin (Dowex Marathon A, hydroxide
form) in water, and the product was titrated using a Mettler-Toledo
DL22 autotitrator using 0.01 M HCl as the titrant.
TABLE-US-00004 TABLE 3 Syntheses and Characterizations of
Imidazolium Structure Directing Agents Reaction Organic Parent
Imidazole Supplier Type .sup.13C NMR .delta. (ppm) 1
N-methylimidazole Aldrich 1 36.32, 123.76, 136.86 2
1,2-Dimethylimidazole Aldrich 1 8.52, 34.48, 121.64, 144.63 3
4-methylimidazole Aldrich 2 8.52, 33.37, 35.87, 120.37, 132.33,
135.86 4 2-ethylimidazole Aldrich 2 9.92, 16.59, 34.71, 122.07,
148.16 5 2,4-dimethylimidazole Synquest 2 8.62, 9.38, 31.46, 34.36,
118.64, 130.14, 143.89 6 2-ethyl-4-methylimidazole Aldrich 2 8.80,
10.17, 16.93, 31.52, 34.36, 118.83, 120.23, 130.23, 147.32 7
2-isopropylimidazole TCI 2 17.55, 24.79, 35.68, 122.65, 149.69 8
1,2,4,5- TCI 1 7.99, 9.76, 31.58, 125.42, tetramethylimidazole
142.21
[0287] The linked quaternary imidazolium cation OSDAs used in this
work were synthesized by reacting 200 mmol of
1,2,4,5-tetramethylimidazole (TCI Chemicals) with 100 mmol of
either 1,5-dibromopentane, 1,4-dibromobutane, or 1,3-dibromopropane
(all from Aldrich) at reflux in methanol overnight. The solvent was
then removed using rotary evaporation and the product washed with
ether. The products were verified using .sup.13C NMR in D.sub.2O
with methanol added as an internal standard. .sup.13C-NMR (125 MHz,
D.sub.2O), pentane linked pentamethyl imidazolium cations: .delta.
7.76, 7.82, 9.61, 22.82, 28.58, 31.42, 44.72, 124.84, 126.03,
141.95. .sup.13C-NMR (125 MHz, D.sub.2O), butane linked pentamethyl
imidazolium cations: .delta. 7.56, 9.35, 25.88, 30.17, 21.21,
44.14, 124.60, 126.00, 141.89. HRMS-FAB (m/z): [M+H] calculated for
C.sub.18H.sub.31N.sub.4, 303.25; found, 303.26. The products were
ion exchanged and titrated as described above.
Example 3.1. General Methods for Preparation of Crystalline
Microporous Silicate or Aluminosilicate Solids Using Imidazolium
Cations
[0288] The following general synthesis procedures were used in the
preparation of the microporous materials can be found below. In all
situations where a rotating oven was used the samples were spun at
63 rpm. All powder x-ray diffraction characterization was conducted
on a Rigaku MiniFlex II with Cu K.alpha. radiation.
Example 3.2. Fluoride Mediated Reactions
[0289] A general procedure for a fluoride mediated synthesis was as
follows. Tetraethylorthosilicate (TEOS) and aluminum isopropoxide
(if necessary) were added to the OSDA in its hydroxide form in a
Teflon Parr reactor liner. The container was closed and stirred for
at least 12 hours to allow for complete hydrolysis. The lid was
then removed and the alcohol and appropriate amount of water were
allowed to evaporate under a stream of air. The composition was
monitored gravimetrically. Additional water was added as necessary,
and then aqueous HF (Aldrich) was added and the mixture was stirred
by hand until a homogenous gel was obtained. (Caution: Use
appropriate personal protective equipment, ventilation and other
safety measures when working with HF.) In some cases, the final
molar ratios of the gel were: [0290] (1-x) SiO.sub.2:x Al:0.5
ROH:0.5HF:y H.sub.2O.
[0291] In those experiments involving pure silica gels or gels
evaluating OSDAs other than pentamethyl imidazolium hydroxide in
RTH syntheses, the final gel molar ratios were: [0292] 1
SiO.sub.2:0.5 ROH:0.5 HF:x H.sub.2O, x=4, 7 [0293] 0.95
SiO.sub.2:0.05 Al:0.5 ROH:0.5 HF:4 H.sub.2O
[0294] In other cases where the final compositions were Si/Al=15
(i.e., in forming the CIT-7 compositions), the final molar ratios
were: [0295] 1 SiO.sub.2: 0.0333 Al:0.08 Na.sub.2O:0.16 ROH:30
H.sub.2O
[0296] The parameters x and y were varied depending on the
synthesis and the desired composition. For low water syntheses, a
final evaporation step was used after the addition of HF to reach
the desired water ratio. The Teflon-lined Parr reactor was sealed
and placed in a rotating oven at 160.degree. C. or 175.degree. C.
Aliquots of the material were taken periodically by first quenching
the reactor in water and then removing enough material for powder
X-ray diffraction (PXRD).
Example 3.3. Hydroxide Mediated Reactions
[0297] For the hydroxide syntheses, several variations on gel Si/Al
as well as the sources of silica and alumina were used. Specific
synthesis preparations are below. For all hydroxide reactions,
seeds were added after 1 day at reaction temperature, once a
decrease in pH was observed. Normally seeds were added as a
homogeneous aliquot of the contents of a previous, completed
reaction (less than 0.3 mL) as these were found to be more active
than seeds that had been washed. The use of seeds was found to
speed the formation of RTH and to help avoid the formation of dense
phases, but this influence was not extensively investigated.
Aliquots were taken periodically, and crystallization was monitored
by both PXRD and pH, as an increase in pH was generally observed
when the product crystallized. After the product crystallized, the
material was washed with DI water and then collected via
centrifugation. This process was repeated at least three times, and
a final wash was performed using acetone. The product was dried at
100.degree. C. in air.
Example 3.4. Sodium Aluminate (or Reheiss F-2000) and Ludox AS-40
(or Cabosil)
[0298] The OSDA in its hydroxide form, sodium hydroxide (if
necessary), any necessary water and sodium aluminate (Pfaltz &
Bauer) were combined in a Teflon Parr reactor liner and stirred
until the sodium aluminate completely dissolved. Ludox AS-40
(Aldrich) was then added and stirred until a homogenous gel was
obtained. In sodium-free syntheses, Reheiss F-2000 (55 wt %
Al.sub.2O.sub.3) was used as the source of aluminum instead of
sodium aluminate, and Cabosil M-5 was used instead of Ludox AS-40.
The gel pH was measured, and then the Teflon-lined Parr reactor was
placed in a rotating oven at 160.degree. C.
Example 3.5. Si/Al=15 (NH.sub.4--Y and Sodium Silicate)
[0299] Following the method of Wagner et al., J. Am. Chem. Soc.
2000, 122, 263, 2 mmol of the OSDA in its hydroxide form was mixed
with 0.20 g of 1 M NaOH, and water was added to give a total mass
of 6 g. Then 2.5 grams of sodium silicate (PQ Corporation, 28.6 wt
% SiO.sub.2 and 8.9 wt % Na.sub.2O) was added to the mixture and
finally 0.25 g of NH.sub.4--Y (Zeolyst CBV 500, Si/Al=2.55) was
added. The solution was heated at 140.degree. C. in a rotating
oven.
Example 3.6. Si/Al=15 (CBV 720)
[0300] 3 mmol of the OSDA in its hydroxide form was mixed with 1 g
of 1 M NaOH and water was added to bring the total mass to 7 g.
Then 1 g of CBV 720 (Zeolyst, Si/Al=15) was added. The solution was
heated at 175.degree. C. in a rotating oven.
Example 3.7. Si/Al=30 (CBV 760)
[0301] 3 mmol of the OSDA in its hydroxide form was mixed with 1 g
of 1 M NaOH and water was added to bring the total mass to 7 g.
Then 1 g of CBV 760 (Zeolyst. Si/Al=30) was added. The solution was
heated at 175.degree. C. in a rotating oven.
Example 3.8. SSZ-13 Synthesis
[0302] SSZ-13 was synthesized using a standard method of Robson, H.
Verified synthesis of zeolitic materials; 2001. In a typical
preparation, 3.33 g of 1 M NaOH was mixed with 2.81 g of
N,N,N-trimethyl-1-adamantammonium hydroxide (Sachem, 1.18 mmol
OH/g) and 6.62 g of water. Then 0.077 g of Reheiss F-2000 (55 wt %
Al.sub.2O.sub.3) was added and stirred until the solution cleared.
Finally, 1.00 g of Cabosil M-5 was added and stirred until a
homogeneous solution was obtained. The solution was heated at
160.degree. C. in a rotating oven for approximately 6 days.
Example 3.9. SAPO-34 Synthesis
[0303] SAPO-34 was prepared from the following gel composition:
0.5(TEA).sub.2O:1.5Pr.sub.2NH:0.6SiO.sub.2:1Al.sub.2O.sub.3:1P.sub.2O.sub-
.5:70H.sub.2O. In a typical preparation, 11.5 g of 85 wt %
phosphoric acid were dissolved in 4.35 g of water and stirred for 5
minutes. Then 6.875 g of Catapal B alumina were added to 20 g of
water and stirred for 10 minutes. The mixtures were then slowly
combined and stirred for 1 hour at room temperature. Next 4.48 g of
Ludox HS-40 was added and stirred by hand until a homogenous gel
was obtained. Then 20.8 g of 35 wt % TEAOH and 7.61 g of
dipropylamine were added and the gel was homogenized by manual
stirring. Then the gel was stirred at room temperature for 2 hours.
Finally, the gel was added to a Teflon-lined Parr reactor and
heated at 200.degree. C. without stirring for 24 hours.
Example 3.10. Si/Al=50 (Ludox AS-40 and Sodium Aluminate)
[0304] 4 mmol of the OSDA in its hydroxide form was mixed with 1.56
g of 1 M NaOH and the total mass was brought to 9.66 g with the
addition of water. Then 0.038 g of sodium aluminate (Pfaltz &
Bauer) was added and stirred until dissolved. Finally 3 g of Ludox
AS-40 was added and stirred until a homogeneous gel was obtained.
Seeds were added and then the gel was heated at 160.degree. C. in a
rotating oven.
Example 3.11. Tosoh 390HUA Reaction
[0305] Following the method of Zones et al., Chem. Mater., 26
(2014) 3909-3913, 3 mmol of the OSDA in its hydroxide form and 0.75
g of 1 M KOH were added to a Teflon Parr Reactor. Then 0.92 g of
Tosoh 390HUA was added (highly dealuminated FAU with
Si/Al.about.250) and the mixture was stirred until homogeneous. The
gel was heated at 175.degree. C. in a rotating oven.
Example 3.12. Calcination
[0306] All products were calcined in breathing grade air. The
material was heated to 150.degree. C. at 1.degree. C./min under
flowing air, held for three hours, then heated to 580.degree. C. at
1.degree. C./min and held for 6-12 hours under flowing air to
assure complete combustion of the organic.
Example 4. Reaction Testing of RTH Materials
[0307] Prior to reaction testing, all materials were calcined as
described above. After calcination they were exchanged to ammonium
form using 1 M NH.sub.4NO.sub.3 (100 mL of solution per gram of
catalyst) at 95.degree. C. with stirring for three hours, this was
done a total of three times per sample. After ammonium exchange the
materials were washed with water and dried and then calcined. The
calcined materials were then pelletized, crushed, and sieved.
Particles between 0.6 mm and 0.18 mm were supported between glass
wool beds in an Autoclave Engineers BTRS, Jr. SS-316 tubular,
continuous flow reactor.
[0308] All catalysts were dried at 150.degree. C. in situ in a 30
cm.sup.3/min flow of 5% Ar/95% He for 4 h prior to the reaction.
The reactions were conducted at 400.degree. C. in a 10%
methanol/inert flow. Methanol was introduced via a liquid syringe
pump at 5.4 .mu.L/min, into a gas stream of the inert blend at 30
cm.sup.3/min. The reactant flow had a weight hourly space velocity
of 1.3 h.sup.-1. In a typical run, 200 mg of dry catalyst was
loaded. Effluent gases were evaluated using an on-stream GC/MS
(Agilent GC 6890/MSD5793N) with a Plot-Q capillary column
installed. Conversions and selectivities were computed on a carbon
mole basis. Catalyst regeneration between reaction tests was done
in-situ by exposing the catalyst to breathing grade air at reaction
temperature, ramping to 580.degree. C. at 1.degree. C./min, holding
at 580.degree. C. for 6 hours, and then cooling to reaction
temperature.
Example 5. Results
[0309] In pure silicate systems, as well as germanosilicate
systems, the mono-imidazolium cations directed the formation of
STW. However, when aluminum was introduced into the system the
product was aluminosilicate RTH. In the initial series of
experiments, the reaction conditions were those shown in Table 4. A
representative powder X-ray diffraction pattern of one of the
materials obtained is shown in FIG. 1. All peaks matched those
reported for the spectrum for RTH.
TABLE-US-00005 TABLE 4 RTH Synthesis Conditions. Experimental
Series #1 Temp, Time, Si Al R.sup.+ F.sup.- H.sub.2O .degree. C.
days Results Comments 1 0.02 0.5 0.5 14 160 12 RTH 1 0.05 0.5 0.5
14 160 12 RTH 1 0.05 0.5 0.5 4 160 10 RTH 1 0.05 0.5 0.5 4 160 10
RTH 1 0.05 0.5 0.5 7 160 4 RTH + STW STW seeds added Molar ratios
of materials based on Si = 1 R.sup.+ refers to
pentamethylimidazolium cation
[0310] Subsequent experiments were directed to expanding the range
of compositions (Table 5). In these experiments, it was shown that
the fluoride method was able to produce RTH across a wide range of
compositions, but at the highest Si/Al ratios tested, STW appeared
as a competitive phase (sample F9). The crystal sizes and
morphologies were consistent with pure-silicate RTH produced in
fluoride media, and the large crystal size was what is generally
observed for low-water, fluoride-mediated syntheses. Comparison of
.sup.13C CP-MAS NMR spectra of the as-synthesized RTH zeolite with
a solution spectrum of the pentamethylimidazolium ion in D.sub.2O
showed that it was this cation, and not a decomposition product,
that led to the formation of aluminosilicate RTH. See FIG. 5. In
order to determine the coordination of the aluminum in the
material, .sup.27Al MAS NMR was performed on the calcined sample
containing the highest amount of aluminum (sample F2), and the
spectrum is shown in FIG. 6. The single resonance in this sample at
54 ppm is consistent with tetrahedrally coordinated aluminum, and
there is no evidence of octahedrally coordinated aluminum, normally
found around 0 ppm.
TABLE-US-00006 TABLE 5 RTH Synthesis in Fluoride Media.
Experimental Series #2 Gel Si/Al Product Si/Al* Gel
H.sub.2O/SiO.sub.2 Time, days Sample 5 -- 7 No product F1 10 7 7 29
F2 15 10 14 46 F3 20 16 14 22 F4 20 18 4 10 F5 33 22 14 20 F6 40 26
14 17 F7 50 27 14 20 F8 150 STW impurity 7 7 F9 *Reported Si/Al
ratio is of calcined materials
[0311] The success of using pentamethylimidazolium in
fluoride-mediated reactions to produce aluminosilicate RTH led to
work in hydroxide-mediated reactions as well, with seeds of RTH
added to promote its formation. The results of the syntheses are
shown in Table 6. In general, these syntheses were found to be
sensitive to reaction time and temperature, and required careful
monitoring to avoid the formation of dense phases. Seeds of RTH
were added to all reactions to promote the formation of RTH, but
the exact influence of the seeds was not extensively investigated.
A representative PXRD of the calcined material produced in
hydroxide media is shown in FIG. 2. The crystal sizes of the
products were generally much smaller in hydroxide syntheses than in
the fluoride syntheses, as is shown in FIG. 4A-C. The smaller
crystal sizes observed under these conditions are consistent with
what is generally reported in hydroxide syntheses. It is
interesting to note that the aggregation appeared to be different
in reactions where no sodium was present compared to those with
sodium present (FIG. 4A-C). .sup.13C CP-MAS NMR showed that
pentamethylimidazolium was also occluded intact in the material
prepared in hydroxide media (FIG. 4A-C). .sup.27Al MAS NMR was used
to characterize the sample containing the largest amount of
aluminum (sample H1), as was done in the fluoride-mediated case,
and is shown in FIG. 6. There is a single resonance at 54 ppm
corresponding to tetrahedrally coordinated aluminum and no evidence
of any significant amount of octahedral aluminum. An argon
adsorption isotherm for sample H4 is shown in FIG. 7, and the
micropore volume was calculated to be 0.16 cm.sup.3/g (t-plot
method). The EDS analyses of the materials synthesized in hydroxide
media are given in Table 6, and the results show that RTH can be
crystallized across a wide range of compositions from Si/Al of 6 to
59 in the calcined product (a large expansion over previously
reported results). Of significant interest are the low-silica
syntheses (the lowest product found was Si/Al=6, sample H1), much
lower than any other reported compositions.
TABLE-US-00007 TABLE 6 RTH Synthesis in Hydroxide Media.
Experimental Series #3 Gel Product Gel Gel Gel Time, Si/Al
Si/Al.sup.a Na/Si ROH/Si H.sub.2O/Si days Sample 5.sup.b 6 0.16
0.16 30 10 H1 10.sup.b 9 0.16 0.16 30 10 H2 15.sup.c 9 9 H3
15.sup.b 14 0.16 0.16 30 10 H4 15.sup.d 15 0.32 30 15 H5 15.sup.e
17 10 H6 20.sup.b 20 0.16 0.16 30 12 H7 30.sup.f 29 13 H8 50.sup.b
45 0.10 0.20 30 9 H9 75.sup.b 59 0.10 0.20 30 9 H10 .sup.aReported
Si/Al ratio is of calcined material; .sup.bMade with Ludox AS-40
and sodium aluminate; .sup.cMade with NH.sub.4--Y and sodium
silicate; .sup.dMade using Cabosil M-5 and Reheiss F-2000;
.sup.eMade using CBV 720 as only source of Si and Al; .sup.fMade
using CBV 760 as only source of Si and Al.
Example 6: Reaction Testing
[0312] The catalytic activity of RTH for the MTO reaction was
evaluated using three different samples of RTH prepared in
hydroxide media at different Si/Al ratios, and the results were
compared to samples of SSZ-13 and SAPO-34. The samples of RTH
tested were prepared using the CBV 720, CBV 760 and the sodium
aluminate and Ludox synthesis routes, with product Si/Al values of
17, 29 and 59, respectively (samples H6, H8, H10). The sample of
SSZ-13 had a product Si/Al of 19. The MTO reaction data for the
SSZ-13 and SAPO-34 are given in FIG. 8A and FIG. 8B, for the RTH
materials is given in FIG. 8C-G.
[0313] The propylene to ethylene ratio was much higher for RTH than
SSZ-13 or SAPO-34. In sample H6 with Si/Al=17, the maximum
propylene to ethylene selectivity ratio observed was 3.6 at 96
minutes on stream. For sample H8 with Si/Al=29, the maximum
propylene to ethylene selectivity ratio observed was 3.9 at 96
minutes on stream. For sample H10 with Si/Al=59, the maximum
propylene to ethylene selectivity ratio observed was 3.6 between 25
and 41 minutes on stream. These selectivity ratios are much higher
than those observed with SSZ-13 or SAPO-34, where the maximum
propylene to ethylene ratios are 1.7 at 96 minutes on stream and
1.3 across several time points, respectively (FIGS. 8A and 8B).
This result shows that RTH would be a superior catalyst in
applications where a higher propylene to ethylene ratio is
desired.
[0314] The selectivity towards butene was also higher for RTH than
for SSZ-13 or SAPO-34. The maximum selectivities to butene for the
RTH samples were 0.22, 0.27 and 0.25 for the samples with Si/Al=17,
29 and 59, respectively (H6, H8, H10). The highest selectivity
observed for SSZ-13 was 0.15 and for SAPO-34 was 0.17 (FIGS. 8A and
8B).
[0315] With the RTH samples, one of the main differences between
the samples was the selectivity to C.sub.1-C.sub.4 saturates
(mainly propane). The maximum selectivity for each sample occurred
at the first time point, and the values were 0.39, 0.28 and 0.19
for the samples with Si/Al=17, 29 and 59, respectively (samples H6,
H8, H10). It was also observed that time on stream with complete
methanol conversion decreased with increasing Si/Al ratios.
[0316] When comparing RTH to SSZ-13 or SAPO-34, one of the main
differences observed was the time on stream until the catalyst
deactivated. In all the RTH samples, this was significantly less
than it was for either SSZ-13 or SAPO-34. However, an industrial
scale MTO reaction will likely be run in a fluidized-bed reactor,
which allows continuous regeneration of the catalyst. This will
allow a system to be operated at any time point along a fixed bed
reactor profile, assuming the catalyst can be regenerated. To this
end, the ability of RTH to be regenerated was tested by running the
Si/Al=17 material (sample H6) for three consecutive MTO reaction
runs with regeneration between each run, and the results are given
in FIGS. 8C-D. There are some small differences between the fresh
catalyst (FIG. 8C) and first regeneration of the catalyst (FIG.
8D), but the MTO reaction behavior is similar between the first
regeneration (FIG. 8D) and second regeneration (FIG. 8E) of the
material. The regeneration experiment demonstrates that RTH would
be suitable for use in fluidized bed systems as it can maintain its
activity across multiple regeneration cycles.
Example 7: Testing Additional Imidazolium Cations
Example 7.1. Syntheses of Aluminosilicate RTH
[0317] Results of the imidazolium screening reactions are given in
Table 7. It was found that nearly all of the imidazolium screened
in this study led to the formation of RTH. The simplest imidazolium
OSDA, 1, did not produce RTH and was found to decompose under many
of the conditions tested in this study. It was found to produce
materials in fluoride mediated reactions, consistent with those
previously reported, so the instability is property of the organic.
Additionally, OSDA 7 was also unstable under many of the conditions
tested in these screening reactions, and was not found to lead to
RTH under any conditions tested.
[0318] All of the other OSDAs tested were able to produce
aluminosilicate RTH under a majority of the inorganic conditions
tested. The formation of aluminosilicate RTH using
pentamethylimidazolium was first observed in fluoride-mediated
aluminosilicate conditions, and OSDAs 2-6, 8 were all able to
produce RTH under this condition, without the use of seeds. Under
more conventional, hydroxide-mediated conditions, they were also
observed to form RTH across a wide compositional range. In some
cases, such as with OSDAs 2-4 the use of seeds was found to be
necessary to cause the formation of RTH. This suggests that these
organics were less directing to RTH, but are still able to form the
material when nucleation is induced through seeding. The OSDAs
found to be the most strongly directing to RTH were 2, 5 and 8.
Example 7.2. Pure-Silica RTH
[0319] None of the mono-quat imidazolium examined in this study was
able to produce pure-silica RTH. The only previously reported
method to make this material uses a difficult to produce OSDA (see
Background, above). Recent investigations by the present inventors
have examined linked pairs of quaternary imidazolium cations
("diquats") produced using tetramethylimidazole. The diquat with a
5-carbon linker in low-water, fluoride-mediated reactions was found
to produce pure-silica RTH at H.sub.2O/Si.sub.2O=4, in competition
with BEA, STW and CIT-7. From the as-made material. FIG. 9, lower
trace) it was not obvious that the material produced is RTH, this
was only apparent upon calcination. Initially, it was thought that
the RTH was formed through topotactic condensation. This was tested
by treating the material in ozone at 150.degree. C., below the
temperature at which topotactic condensation is reported to occur,
which is above 500.degree. C. Under these conditions the formation
of RTH was also apparent, and the similarity of the as-made and
calcined PXRD samples suggests that it is likely that the PXRD of
the as-made material was due to the organic phase. This is only the
second report of pure silica RTH and in this method the organic is
accessible in only a single step.
TABLE-US-00008 TABLE 7 Results of various microporous materials
syntheses. Pure Si Pure Si fluoride, fluoride, Tosoh H.sub.2O/
H.sub.2O/ Si/Al = Si/Al = Si/Al = CBV720 CBV720 CBV760 CBV760 Si/Al
= 390, SiO.sub.2 = 4, SiO.sub.2 = 7, 20 15 15 160.degree. C.,
160.degree. C., 175.degree. C., 175.degree. C., 50 175.degree. C.,
Organic Number 175.degree. C. 175.degree. C. fluoride Seeds no
seeds seeds no seeds seeds no seeds seeds no seeds ##STR00021## 1
TON TON FER OD OD OD TON TON ZSM-48 + D ##STR00022## 2 ITW ITW RTH
RTH RTH RTH RTH OD RTH D ##STR00023## 3 ITW ITW RTH RTH MOR OD OD
TON OD TON ZSM-48 ##STR00024## 4 CIT-7, ITW, STW, STF, MTW ITW RTH
RTH RTH RTH OD OD OD MTW D ##STR00025## 5 STW STW RTH RTH RTH + MOR
RTH RTH RTH RTH D ##STR00026## 6 STW HPM-2 RTH RTH MOR + RTH OD OD
OD OD MTW D ##STR00027## 7 STF ?? ?? MOR MOR OD OD OD ##STR00028##
8 STW STW RTH RTH RTH RTH RTH RTH RTH RTH D OD = Organic Decomposed
A = Material was still amorphous after 30 days but it was not
apparent that the organic had degraded. D = Dense Phase ?? Product
could not be identified
Example 8.1: Investigations into the Preparation of CIT-7
[0320] The OSDAs used to produce CIT-7 were
2-ethyl-1,3-dimethylimidazolium (1) and
3,3'-(butane-1,4-diyl)bis(1,2,4,5-tetramethyl-1H-imidazol-3-ium)
(2) and are shown as:
##STR00029##
The synthesis and characterization details for these OSDAs can be
found in Example 1.
[0321] A wide range of products could be produced with the
2-ethyl-1,3-dimethylimidazolium cation in fluoride-mediate,
pure-silica reactions depending on the specific inorganic
conditions used such as H.sub.2O/SiO.sub.2 ratio and temperature.
Results of syntheses over a wide range of conditions are given in
Table 8.
TABLE-US-00009 TABLE 8 Pure-silica fluoride-mediated syntheses
using 2-ethyl-1,3- dimethylimidazolium cation H.sub.2O/SiO.sub.2
Temperature (.degree. C.) Result 2 140 Unknown 4 140 STF 7 140 Amph
14 140 Amph 2 160 ITW 4 160 STW + ITW 7 160 ITW + MTW 14 160 ITW 2
175 STW 4 175 Unknown 7 175 ITW 14 175 MTW 2 175 STE + CIT-7 + ITW
2.5 175 CIT-7 3 175 CIT-7 3.5 175 ITW + CIT-7 4 (13 separate
trials).sup.a 175 CIT-7 + ITW 4.5 175 CIT-7 + STW 5 175 ITW +
Unknown 6 175 Pending Unknown means products could not be
identified. In reactions with multiple products phase mixtures were
found but relative amounts were not quantified .sup.aSeeds of CIT-7
were added
[0322] Many known products emerged in these syntheses such as ITW,
MTW, STF and STW as well as a few products that could not be
characterized. In particular at low H.sub.2O/SiO.sub.2 ratios at
175.degree. C. a phase was identified using powder x-ray
diffraction (XRD) that was not a known microporous material phase.
However, this phase was typically found as a phase mixture with
either ITW or STW. A representative XRD of a calcined, pure-silica
material made with 2-ethyl-1,3-dimethylimidazolium cation
containing both CIT-7 as well as an ITW impurity is shown in FIG.
10. It was found that the use of seeds of CIT-7 helped to avoid the
formation of ITW or STW, but it was found to be difficult to avoid
the formation of any competing phases. At H.sub.2O/SiO.sub.2=2.5
and 3 it was not possible to detect any impurity phases using XRD,
but in general it was difficult to synthesize a sample of pure
CIT-7 using 2-ethyl-1,3-dimethylimidazolium cation as it is able to
form many competing phases.
[0323] In addition to these imidazolium based OSDAs, additional
studies into the use of linked pairs of quaternary imidazolium
cations, having differing carbon chain lengths between the
imidazolium moieties, such as shown here:
##STR00030##
have been used in pure-silica, fluoride-mediated syntheses at
175.degree. C. and aluminosilicate, hydroxide-mediated syntheses
with Si/Al=15 at 160.degree. C. Representative results for various
carbon linker chain lengths are given in Table 9.
TABLE-US-00010 TABLE 9 Synthesis results using
tetramethylimidazolium diquats of varying carbon linker length
H.sub.2O/ H.sub.2O/ Si/Al = Si/ Si/ SiO.sub.2 = 4, SiO.sub.2 = 7,
10, Al = 15, Al = 30, Organic 175.degree. C. 175.degree. C.
hydroxide hydroxide hydroxide 3 carbon STW Amorphous Amor- linker
phous 4 carbon CIT-7, STW + IWV linker STW Layered 5 carbon RTH BEA
IWV IWV IWV linker 6 carbon BEA BEA IWV IWV linker
For the 4, 5 and 6 carbon linkers in the aluminosilicate hydroxide
reactions the IWV framework was found as the product. This
framework has been previously reported using
dimethyldiphenylphosphonium in fluoride-mediated, low-water
aluminosilicate reactions but takes a long time to form (49 days)
and is known as ITQ-27. See, e.g., U.S. Pat. No. 7,527,782. It
contains a 2-dimensional channel system of 12-membered rings that
also contains 14-membered rings that are only accessible through
14-membered rings. The present method is simpler, and provides for
a wider range of high Si:Al compositions.
[0324] In the pure-silica, fluoride-mediated reactions at
175.degree. C. a wide variety of products have been observed
depending on chain-length and water content (Table 9). Finding BEA
as a product in these situations is not surprising as it has been
found to form with similar diquats. See, e.g., A. Jackowski, et
al., J. Am. Chem. Soc. 131 (2009) 1092-100. Of the other products
found in these reactions, STW and RTH have been found to form with
pentamethylimidazolium, the similar nature of these diquats to
pentamethylimidazolium makes these expected results. Using the
diquat with a 4 carbon chain linker (the
3,3'-(butane-1,4-diyl)bis(1,2,4,5-tetramethyl-1H-imidazol-3-ium)
dication) led to the formation of CIT-7 in the pure silica
syntheses with H.sub.2O/SiO.sub.2=4. In some instances STW was
found as a competing phase, but it was simple to direct the
formation to pure CIT-7 by adding seeds of CIT-7. A representative
XRD of calcined, pure-silica CIT-7 produced in fluoride media using
the
3,3'-(butane-1,4-diyl)bis(1,2,4,5-tetramethyl-1H-imidazol-3-ium)
dication is shown in FIG. 11.
[0325] The results of more expanded studies using
3,3'-(butane-1,4-diyl)bis(1,2,4,5-tetramethyl-1H-imidazol-3-ium)
dication are shown in Table 9A and Table 9B. In fluoride mediated
reactions CIT-7 was produced with gel compositions of Si/Al=25, 50,
100, 250 and in hydroxide mediated reactions CIT-7 was produced
with a gel composition of Si/Al=15. With H.sub.2O/SiO.sub.2=7, in
fluoride mediated reactions, the product was pure-silica STW (Table
9A). This phase has already been reported using several different
imidazolium based OSDAs. When the water contents of the reactions
were decreased to H.sub.2O/SiO.sub.2=4, the OSDA led to the
formation of a previously unknown phase. The XPD of the calcined
material is shown in FIG. 11. Under these synthesis conditions,
CIT-7 was found to crystallize along with STW as a competing phase,
so care had to be taken to avoid the formation of STW. Once a
pure-phase CIT-7 was obtained, seeds of CIT-7 were used in
subsequent reactions to favor its formation over that of STW. In
hydroxide mediated reactions, at Si/Al=15 (Table 9B), without the
addition of seeds, IWV was found as the product. See FIG. 26A/B.
IWV is a 2-dimensional, 12-membered ring material that contains
14-membered rings that are only accessible through 12-membered
rings. The aluminosilicate was first reported as ITQ-27, and was
made using diphenyldimethylphosphonium as the OSDA. The synthesis
is only reported at a difficult to achieve composition of:
1SiO.sub.2:0.014Al.sub.2O.sub.3:0.50Me.sub.2Ph.sub.2POH:0.50HF:4.2H.sub.2-
O, and takes 59 days to form, the addition of seeds only shortens
this by one week.
[0326] With the addition of pure-silica CIT-7 seeds to the
aluminosilicate syntheses in hydroxide media, CIT-7 was produced
instead of IWV. Aluminosilicate CIT-7 could be easily obtained in
hydroxide media at gel compositions of Si/Al=5-15. Higher silica
compositions led to products containing CIT-7 along with dense
phases or ITQ-27. It is likely that optimizing these synthesis
conditions will lead to higher silica products using a hydroxide
mediated synthesis, however, these compositions are already
accessible using the fluoride method. To demonstrate that the
aluminum was in the framework, the calcined samples with the
highest aluminum contents in both fluoride and hydroxide media were
investigated by using .sup.27Al NMR (FIG. 24). In the sample
prepared in hydroxide media, 95% of the aluminum was tetrahedral,
and in the sample synthesized in fluoride media 88% was in
tetrahedral coordination. In both of these samples, the majority of
the aluminum was in tetrahedral coordination, demonstrating
incorporation in the framework. The Si/Al range over which CIT-7
can be produced will allow for a wide variety of catalytic testing
to be performed.
[0327] An XRD of calcined aluminosilicate CIT-7 made with gel
Si/Al=50 in fluoride media is shown in FIG. 12 and an XRD of the
as-made material produced in hydroxide media with gel Si/Al=15 is
shown in FIG. 13.
TABLE-US-00011 TABLE 9A Fluoride mediated synthesis results using 4
carbon chain linked diquat Gel Ratios Temp Time Product
Ratios.sup.b Si/Al Si/Ti H.sub.2O/SiO.sub.2 Seeds (.degree. C.)
(days) Result Si/Al Si/Ti .infin. -- 4 None 175 8 STW.sup.a -- --
.infin. -- 4 None 175 6 STW + CIT-7.sup.a -- -- .infin. -- 4 None
175 6 CIT-7.sup.a -- -- .infin. -- 4 Silica CIT-7 175 6 CIT-7 -- --
.infin. -- 7 None 175 6 STW -- -- 15 -- 4 Silica CIT-7 175 5 CIT-7
10 -- 15 -- 4 Silica CIT-7 175 5 CIT-8P 20 -- 4 None 175 20 CIT-7
14 -- 20 -- 4 None 175 12 CIT-7 13 -- 25 -- 4 Silica CIT-7 175 5
CIT-7 15 -- 25 -- 4 Silica CIT-7 175 5 CIT-7 17 -- 25 -- 4 Silica
CIT-7 175 6 CIT-7 14 -- 50 -- 4 None 175 18 CIT-7 27 -- 50 -- 4
Silica CIT-7 175 4 CIT-7 28 -- 100 -- 4 Silica CIT-7 175 4 CIT-7 36
-- 250 -- 4 Silica CIT-7 175 4 CIT-7 225 -- -- 50 4 Silica CIT-7
175 7 CIT-7 -- 63 -- 100 4 Silica CIT-7 175 7 CIT-7 -- 88
.sup.aSince STW and CIT-7 were competing products some syntheses
produced pure phase versions (per XPD) of those molecular sieves
.sup.bDetermined using EDS of calcined material
TABLE-US-00012 TABLE 9B Hydroxide mediated synthesis results using
4 carbon chain linked diquat. Gel Gel Gel Gel Temp Time Product
Si/Al Na/Si ROH/Si H.sub.2O/Si (.degree. C.) Seeds (days) Product
Si/Al 5.sup.a 0.25 0.16 30 160 Silica CIT-7 35 CIT-7 9 10.sup.a
0.25 0.16 30 160 None 20 CIT-7 12 15.sup.a 0.16 0.16 30 160 None 35
IWV 15.sup.a 0.16 0.16 30 160 Silica CIT-7 10 CIT-7 18.4 H.sup.+
form 15.sup.a 0.16 0.16 30 160 Silica CIT-7 10 CIT-7 9 30.sup.b 175
None 18 IWV 29 30.sup.b 175 Silica CIT-7 23 IWV + CIT-7 .sup.aMade
using Ludox AS-40 and sodium aluminate .sup.bMade from CBV760
Example 8.2. Structure of CIT-7
[0328] The structure of pure silica CIT-7 was solved by
3-dimensional electron diffraction tomography data (FIG. 14),
refined by synchrotron X-ray powder diffraction data (FIG. 15).
There are 10 unique/independent T atoms in the unit cell and the
material has P-1 symmetry. The new microporous material structure
has a 2-dimensional 10-/8-ring channel system, with distorted
8-ring channels. The channel dimensions of the material are 6.2
.ANG. *5.1 .ANG. and 5.5 .ANG. *2.9 .ANG. for the 10-membered rings
and 8-membered rings, respectively, and views of the channel
systems are shown in FIG. 16 and FIG. 17.
[0329] The structure of CIT-7 is comprised of two different
secondary building units. The first is the previously observed
[4.sup.25.sup.46.sup.2] mtw unit. The second building unit is a new
[4.sup.45.sup.2] building unit comprised of four 4-rings and two
5-rings and are denoted here cse. This cse building unit has not
been previously reported. Both building units are shown in FIG. 18.
The two building units then assemble to form the 3-dimensional
structure of CIT-7, shown in FIG. 19. Oval 8-rings are created (2.9
.ANG..times.5.5 .ANG. opening, with the oxygen diameter of 2.70
.ANG. subtracted). The layer that has 8-rings, could again link to
itself and form 10-ring channels (5.1 .ANG..times.6.2 .ANG.
opening, with the oxygen diameter of 2.70 .ANG. subtracted) that
are running perpendicular to the layer and intersected by 8-ring
channels. At each intersection, a
[4.sup.85.sup.46.sup.88.sup.210.sup.2] cavity is created (FIG. 19).
Isosurface contours of the final material are shown in FIG. 20. One
of the interesting features of the framework, highlighted in FIG.
20, are the bumps inside the 10-ring system that come from the
8-rings.
[0330] It should be noted that the structure of CIT-7 is not
predicted in any hypothetical zeolite framework databases as these
databases only contain structures having less than 10 unique T
atoms per unit cell. The optimized framework energy of pure-silica
CIT-7 relative to a-quartz, i.e., 16.63 kJ/mol per Si atom, clearly
demonstrates that this structure is energetically favorable.
Example 8.3. Pure Silicate CIT-7 Characterization
[0331] The pure silica CIT-7 produced with the
3,3'-(butane-1,4-diyl)bis(1,2,4,5-tetramethyl-1H-imidazol-3-ium)
dication has been characterized using .sup.13C CP-MAS NMR,
.sup.29Si MAS NMR and Argon adsorption. The .sup.13C CP-MAS NMR of
the as-made material (FIG. 21) showed that the
3,3'-(butane-1,4-diyl)bis(1,2,4,5-tetramethyl-1H-imidazol-3-ium)
dication was occluded intact in the framework, demonstrating that
it was not a decomposition product that formed the CIT-7. The
thermogravimetric analysis showed a weight loss of 22.5 wt %, which
corresponds to 1 molecule of OSDA and 2 fluoride anions per unit
cell. The Argon isotherm of the calcined material (FIG. 22) gave a
micropore volume of 0.19 cm.sup.3/g, which is consistent with the
structure solution. An .sup.19F NMR spectrum of the as-made
material revealed resonances at -45 ppm and -128 ppm. The resonance
at -128 ppm can be assigned to a small amount of SiF.sub.6 in the
sample, and the resonance at -45 ppm is consistent with fluoride
being occluded in a pure-silica material. The .sup.29Si NMR
spectrum of the calcined material is shown in FIG. 23. The spectrum
was deconvoluted using Lorentzian lineshapes and the peak fit is
shown in FIG. 24 along with the extracted parameters in Table
10.
TABLE-US-00013 TABLE 10 Deconvolution parameters determined from
.sup.29Si MAS NMR Spectrum of calcined pure silica CIT-7 along with
the normalized peak areas and assigned T sites Assigned Location
Normalized Area T site Average Si--O--Si Angle.sup.a -115.6 0.92
Si10 152.2 -115.2 2.14 Si3 + Si8 151.7, 151.6 -111.3 1.97 Si1 + Si5
149.4, 149.1 -111.0 1.06 Si6 148.3 -109.6 0.97 Si9 147.2 -109.3
0.88 Si4 147.2 -108.8 1.28 Si7 146.8 -106.7 1.00 Si2 145.6
Example 8.5. X-Ray Analysis of CIT-7
[0332] The structure of the calcined, pure-silica material was
determined using a combination of synchrotron XPD and RED data. The
calcined, pure-silica CIT-7 powder sample was packed into a 0.5 mm
glass capillary and sealed. High-resolution XPD data were then
collected on the 2-1 Powder Diffraction beamline at the Stanford
Synchrotron Radiation Lightsource (SSRL).
[0333] The XPD pattern could be indexed with a triclinic unit cell
(a=13.020 .ANG., b=11.205 .ANG., c=9.375 .ANG.,
.alpha.=92.8.degree., .beta.=107.2.degree., .gamma.=103.3.degree.),
using the program TREOR (as described in P. E. Werner, et al., J.
Appl. Cryst., 1985, 18, 367-370) implemented in the software CMPR
(as described in B. H. Toby, J. Appl. Cryst., 2005, 38, 1040-1041).
No indexing solutions on higher symmetry crystal systems could be
found. Individual reflection intensities were extracted from the
powder pattern to a minimum d-spacing of 0.90 .ANG. (ca.
67.5.degree. 2.theta.) using the program EXTRACT (described in
Baerlocher, C. EXTRACT. A Fortran program for the extraction of
integrated intensities from a powder pattern; Institut fur
Kristallographie, ETH Zurich, Switzerland, 1990) in the XRS-82
suite of programs (see Baerlocher, C.; Hepp, A. XRS-82. X-ray
Rietveld Syst. Inst. fur Krist. ETH Zurich, Switzerland, 1982).
Structure solution using these data was then attempted using both
the zeolite-specific structure-solution program Focus (R. W.
Grosse-Kunstleve, et al., J. Appl. Crystallogr., 1997, 30,
985-995), and the powder charge-flipping algorithm (C. Baerlocher,
et al., Z. Kristallogr., 2007, 222, 47-53) in the program Superflip
(L. Palatinus and G. Chapuis, J. Appl. Cryst., 2007, 40, 786-790.).
Unfortunately, neither approach yielded a reasonable structural
model.
[0334] Therefore, the RED technique was applied to the CIT-7 sample
to obtain 3-dimensional single-crystal data. Two independent RED
data sets were collected on two tiny crystallites, both could be
indexed on triclinic unit cells that are similar to the one found
for the XPD pattern. Reflection intensities (ca. 1.0 .ANG.
resolution) were then extracted for each data set using the RED
software, and were further analyzed by the program Triple (Triple
http//www.calidris-em.com/triple.php. Accessed Dec. 8, 2014).
Although both datasets gave data completeness of only ca. 55%, one
did provide better quality over the other, i.e., the agreement
factor of the reflection intensities for Friedel pairs is 11.7%
versus 22.1%. Therefore, a structure solution attempt using the
better RED dataset for Focus structure solution (assuming the
centro-symmetric space group P-1) was performed. Many framework
topologies were proposed by Focus, but none were chemically
reasonable. Luckily, the two available RED datasets covered
different areas of reciprocal space, and therefore by merging them,
the data completeness could be improved to 86%. With the merged
dataset included in the Focus runs, the structure solution became
surprisingly straightforward. A model with 10 unique framework
T-atoms, clearly showing a 2-dimensional channel system of
intersecting 10- and 8-rings, was revealed. Indeed, this was the
only solution proposed by the structure solution program.
[0335] The geometry of the CIT-7 framework structure model from the
Focus run was optimized using the program DLS-76 (Baerlocher, C.;
Hepp, A.; Meier, W. M. DLS-76; Inst. fur Krist. ETH Zurich,
Switzerland, 1976), and then served as a starting point for
Rietveld refinement, using the synchrotron XPD data. Geometric
restraints were applied on the bond distances and bond angles of
the framework atoms, and their positions refined. These restraints
were imposed throughout the refinement, but their relative
weighting with respect to the XPD data was reduced as the
refinement progressed. The structural model finally converged with
RF=0.055 and R.sub.wp=0.077 (Rexp=0.068). All atoms were refined
isotropically using scattering factors for neutral atoms. The
displacement parameters for similar atoms were constrained to be
equal to keep the number of parameters to a minimum. Details of the
refinement and selected bond distances and angles are given in
Table 11. The fit of the profile calculated from the final model to
the experimental data is shown in FIG. 15.
TABLE-US-00014 TABLE 11 Crystallographic data for pure-silica
CIT-7. Chemical composition [Si.sub.20O.sub.40] Unit cell a (.ANG.)
13.0187(1) B (.ANG.) 11.2063(1) c (.ANG.) 9.3758(1) .alpha.
(.degree.) 92.8224(6) .beta. (.degree.) 107.2048(5) .gamma.
(.degree.) 103.2565(5) Space group P-1 Number of observations 8001
Number of contributing reflections 3703 Number of geometric
restraints 120 Number of structural parameters 98 Number of profile
parameters 12 R.sub.F 0.041 R.sub.wp 0.077 R.sub.exp 0.068 Selected
bond distances (.ANG.) and angles (.degree.) Si--O (.ANG.) min:
1.59 max: 1.62 avg: 1.61 O--Si--O (.degree.) min: 106.4 max: 112.2
avg: 109.5 Si--O--Si (.degree.) min: 142.1 max: 157.3 avg:
148.9
Example 8.4. Titanosilicate CIT-7
[0336] The ability of the CIT-7 framework to incorporate
heteroatoms besides aluminum was tested by adding titanium to
fluoride syntheses. In the titanosilicate material, both Si/Ti=50
and 100 were synthesized. DRUV of the as-made and calcined
titanosilicate materials was used to show that the titanium was
present in tetrahedral coordination (FIG. 25), indicating framework
incorporation.
Example 8.5. Comparison with Other Structures
[0337] The structure solution of CIT-7 shows that it is a unique
framework comprised of a 2-dimensional system of 10- and 8-membered
rings, where the 8-membered rings are elliptical and the
10-membered rings contain "bumps" in them caused by the 8-membered
rings. Due to this unique pore system it is expected that this
material will exhibit unique properties.
[0338] Four other zeolite frameworks, i.e., FER (e.g., NU-23,
ZSM-35), MFS (e.g., ZSM-57), RRO (e.g., RUB-41) and STI (e.g.,
TNU-10, SSZ-75), have a 2-dimensional 10-/8-ring channel systems.
CIT-7 distinguishes itself from these known materials by some
unique structural features. CIT-7 is the only system that has a
large cavity in the intersection region. The maximum included
sphere diameter for the idealized CIT-7 framework (i.e., the one
after distance-angle least-square refinement) is calculated to be
7.91 .ANG., significantly larger than those for the other four
idealized frameworks (Table 12). Also, it should also be noted that
CIT-7 can be made across a very wide Si/Al ratio (9-.infin.) as
well as a titanium (and we suspect other heteroatoms) containing
material. This compositional flexibility, when combined with the
medium-/small-pore channels and intersecting cavities, could be of
interest in a broad spectrum of applications.
TABLE-US-00015 TABLE 12 Comparison of the channel and pore
characteristics for the five 2-D 10-/8-ring zeolites. For the 4
known zeolite frameworks, the channel characteristics are taken
from the literature, and the pore characteristics are taken from
the Database of Zeolite Structures. The channel characteristics for
CIT-7 are calculated using the program "Sphere Viewer". All data
are in .ANG.. Frame- 10-MR 8-MR work D.sub.M D.sub.a D.sub.b
D.sub.c Material opening opening Ideal- 7.91 1.87 2.92 4.67 CIT-7
5.1 .times. 6.2 2.9 .times. 5.5 ized CIT-7 MFS 6.71 5.31 3.14 1.51
ZSM-57 5.1 .times. 5.4 3.3 .times. 4.8 FER 6.25 1.50 3.34 4.63
Ferrierite 4.2 .times. 5.4 3.5 .times. 4.8 STI 6.23 4.88 2.90 1.79
SSZ-75 4.7 .times. 5.0 2.7 .times. 5.6 RRO 4.40 4.03 1.48 3.07
RUB-41 4.0 .times. 6.5 2.7 .times. 5.0 Note: D.sub.M means the
maximum included sphere diameters, D.sub.a, D.sub.b and D.sub.c are
the maximum free sphere diameters that can diffuse along a-, b- and
c-axis, respectively.
Example 8.6. Proposed Uses of Crystalline Solids Containing
8-/10-MRs
[0339] Several systems comprising 2-dimensional systems of 10- and
8-membered rings have been proposed for various applications such
as carbonylation, NOx reduction, dewaxing, cracking, isomerization,
reforming, methanol to olefins reaction, oligmerization, amination
of alcohols, hydroconversion and gas separations and detailed
applications and references for several of the frameworks are given
in Table 13. CIT-7 is expected to be useful in each of these
applications, and the use of this material in these applications is
considered within the scope of the present invention. That is,
various embodiments of the present invention include those where
the named reaction is mediated by CIT-7; i.e., individual
embodiments provide for effecting the named reaction by contacting
an appropriate feedstock with the CIT-7-type material, under
conditions known to be effective for the transformation.
TABLE-US-00016 TABLE 13 Expected uses of microporous material
frameworks with 2-dimensional 10-/8-membered ring systems Framework
Use As Described in: FER (NU- Low temperature carbonylation of DME
with CO Y. Roman-Leshkov, et al., J. 23, Phys. Chem. C. 115 (2011)
ZSM-35) 1096-1102. NOx reduction with methane Y. Li, et al., Appl.
Catal. B Environ. 3 (1993) L1-L11. Dewaxing, cracking,
isomerization and reforming U.S. Pat. No. 4,925,548. (1990)
Polymerization, aromatization, cracking, hydrocracking, U.S. Pat.
No. 4,016,245. converting light aliphatics to aromatics (1977) MFS
(ZSM- Cracking, dehydrogenating, converting paraffins to U.S. Pat.
No. 4,873,067. 57) aromatics, MTO, isomerizing xylenes, (1989)
disproportionating toluene, alkylating aromatic hydrocarbons,
upgrading hydrocarbons 1-Butene Skeletal Isomerization and n-Octane
Cracking S. Lee, et al., J. Catal. 196 (2000) 158-166 Alkene
oligomerization J. A. Martens, et al., Angew. Chemie. 39 (2000)
4376-4379 RRO (RUB- Synthesis of methylamines by the amination of
B. Tijsebaert, et al., J. Catal. 41) methanol 278 (2011) 246-252
and B. Yilmaz, et al., Chem. Commun. (Camb). 47 (2011) 1812-4.
Separation and sorption of C3-C6 alkanes Y. X. Wang, et al., Chem.
Mater. 17 (2005) 43-49 Decane hydroconversion B. Yilmaz, et al.,
Chem. Commun (Camb). 47 (2011) 1812-4. STI (TNU- Skeletal
isomerization of 1-butene to isobutene and the S. B. Hong, et al.,
J. Am. Chem. 10, selective reduction of NO with methane Soc. 126
(2004) 5817-26. SSZ-75) Gas separations, converting oxygenates
(e.g. methanol) U.S. Pat. No. 7,713,512. to olefins, making small
amines, NOx reduction, cold (2010) start hydrocarbon trap
Example 9.1. Synthesis of High Silica Zeolites with the HEU
Topology: Introduction
[0340] New methods have been discovered to produce zeolites with
the HEU framework topology with higher than previously reported
silica to alumina ratios. This material, denoted herein as CIT-8,
can be prepared by both direct synthesis in hydroxide media or as a
topotactic condensation product, where the layered precursor is
made in fluoride media and denoted CIT-8P. These materials are
stable to calcination and subsequent ion exchange (if applicable)
and have micropore volume accessible to nitrogen.
[0341] Zeolites with the HEU framework topology exist as both
natural minerals as well as synthetic analogs. The heulandite
framework consists of a two dimensional channel system. In the
[001] directing there are 10-membered rings (MRs) as well as 8-MRs.
Additionally, there is another set of 8-MRs along with [100]
direction (See Table 1).
[0342] Methods to prepare high silica heulandite, denoted CIT-8,
are reported herein. In one method, CIT-8 is prepared via
topotactic condensation of a layered aluminosilicate material
containing an organic structure directing agent. This layered
material is denoted CIT-8P. CIT-8 can also be prepared by direct
synthesis in hydroxide media using an organic structure directing
agent (OSDA)
Example 9.2. Synthesis of High Silica Zeolites with the HEU and IWV
Topologies: Results
[0343] The diquat used to prepare solids having HEU topology,
3,3'-(butane-1,4-diyl)bis(1,2,4,5-tetramethyl-1H-imidazol-3-ium),
is also described above in the context of CIT-7.
##STR00031##
However, it was found that a certain set of conditions led to the
formation of a new, layered material, denoted CIT-8P. A
representative powder x-ray diffraction pattern (PXRD) of this
material is shown in FIG. 27. This material was produced in
low-water, fluoride-mediated aluminosilicate reactions. The general
composition of these reactions was [0344] 1 SiO.sub.2:x Al:0.5
ROH:0.5 HF:4H.sub.2O and x was varied to give a range of Si/Al
ratios. With Si/Al=15 and 20, pure phase CIT-8P was obtained.
However, at Si/Al=30, 50 and 100 the product was a mixture of
CIT-8P and CIT-7. When CIT-8P was calcined a new phase was found, a
representative XRD pattern is shown in FIG. 28. This material was
identified as having the HEU framework topology. The material with
Si/Al=20 in the gel was found to have a product Si/Al=11.5 and the
nitrogen adsorption isotherm gave a micropore volume of 0.096 cc/g
(t-plot method).
[0345] In changing the OSDA by changing the length of the linker
between the imidazolium groups it was found that diquats of other
linker lengths could also form CIT-8P and CIT-8. Results of the
various synthesis conditions with the diquats are shown in Table
14.
TABLE-US-00017 TABLE 14 Diquat synthesis results in fluoride media,
175.degree. C.: ##STR00032## Linker Pure Si, Pure Si,
H.sub.2O/SiO.sub.2 = 4, H.sub.2O/SiO.sub.2 = 7, H.sub.2O/SiO.sub.2
= 4, H.sub.2O/SiO.sub.2 = 7, length H.sub.2O/SiO.sub.2 = 4
H.sub.2O/SiO.sub.2 = 7 Si/Al = 20 Si/Al = 20 Si/Al = 50 Si/Al = 50
3 STW Amph PREFER CIT-8P + CIT-7 dense PREFER 4 CIT-7, STW +
Layered + CIT-8P CIT-7 CIT-7 CIT-7 CIT-7 STW CIT-7 5 RTH, BEA
CIT-8P CIT-8P CIT-7 + IWV Layered CIT-8P STW 6 BEA BEA CIP-8P BEA
Unknown STF 8 BEA BEA BEA dense BEA BEA 10 BEA MTW BEA BEA BEA
BEA
In general the longest diquats gave products which are commonly
found in microporous materials syntheses such as MTW and BEA.
However, the diquats with carbon chains of 3, 4, and 5 carbon atoms
gave a wide range of interesting products. In pure silica media the
3 carbon diquat gave STW as a product. Under different conditions
this diquat also gave PREFER, which has been previously synthesized
(Schreyeck, L, et al., Microporous Mater. 1996, 6, 259).
[0346] The four carbon diquat also led to a wide variety of
products. This diquat was shown to make CIT-7 in Example 8. In
addition to CIT-7, this diquat also led to CIT-8P. Another product
with this diquat is denoted "Layered+STW." This material is likely
pure silica STW plus some layered material made from the organic
which disappears after calcination.
[0347] Additional experiments showed that the window for producing
the HEU material is narrow, at least for the tested diquat, as
shown in Table 15:
TABLE-US-00018 TABLE 15 Diquat synthesis results in fluoride media,
using the diquat with the four carbon chain linker: ##STR00033##
for the system 1 SiO.sub.2: x Al: 0.5 ROH: 0.5 HF: 4 H.sub.2O: Gel
Gel Gel Gel Temp, Time Product Si/A1 Na/Si ROH/Si H.sub.2O/Si
.degree. C. Seeds (days) Product Si/A1 5 .sup.a 0.25 0.16 30 160
None 43 HEU 7.3 5 .sup.a 0.25 0.16 30 160 Silica 35 CIT-7 9 CIT-7 5
.sup.a 0.25 0.16 30 160 HEU 24 HEU 7.5 .sup.a 0.25 0.16 30 160 HEU
20 CIT-7 10 .sup.a 0.25 0.16 30 160 HEU 20 CIT-7 10 .sup.a 0.25
0.16 30 160 HEU 20 CIT-7 12 15 .sup.a 0.16 0.16 30 160 None 35
CIT-7 15 .sup.a 0.16 0.16 30 160 Silica 10 IWV 18.4 CIT-7 prot.form
15 .sup.a 0.16 0.16 30 160 Silica 10 CIT-7 9 CIT-7 30 .sup.b 175
None 18 IWV 29 30 .sup.b 175 Silica 23 IWV + CIT-7 CIT-7 .sup.a
Made using Ludox AS-40 andsodium aluminate .sup.b Made from
CBV760
[0348] The five carbon diquat led to a wide variety of products. In
the low-water, pure-silica case both RTH and layered STW were
observed as products. The material called layered STW, is different
than the one formed with the four carbon diquat, but is also likely
pure silica STW plus some layered material made from the organic
which disappears after calcination. Besides CIT-7 and CIT-8P the
other product formed by the five carbon diquat was IWV. IWV is a
2-dimensional 12-membered ring material that contains 14-membered
rings which are only accessible through 12-membered rings. This
aluminosilicate was first reported as ITQ-27, and was made using
diphenyldimethylphosphonium as the OSDA. The synthesis is only
reported at a difficult to achieve composition of
1SiO.sub.2:0.014Al.sub.2O.sub.3:0.50Me.sub.2Ph.sub.2POH:0.50HF:4.2H.sub.2-
O, and takes 59 days to form, which can only be shortened by one
week using seeds.
[0349] In hydroxide media using the 4 carbon chain diquat, CIT-8
was found to form by direct synthesis at low Si/Al ratios. With a
gel composition of [0350] 1 SiO.sub.2:0.1 Al.sub.2O.sub.3:0.125
Na.sub.2O:0.16 R.sub.1/2OH:30 H.sub.2O, HEU was found as the
product after 43 days, which could be shortened to 24 days by
adding seeds, a representative PXRD of the calcined material is
shown in FIG. 29. This material was stable to ammonium exchange and
subsequent calcination and it was found that in proton form the
material had a nitrogen adsorption isotherm micropore volume of
0.095 cc/g (t-plot method). The material had an organic content of
8.4 wt % and a product Si/Al=7.3, high than what is reported for
any previous HEU syntheses. When the Si/Al ratio was increased
above about 5 in hydroxide media, CIT-7 was found as the product
instead of HEU, even when seeds were used.
[0351] As those skilled in the art will appreciate, numerous
modifications and variations of the present invention are possible
in light of these teachings, and all such are contemplated hereby.
For example, in addition to the embodiments described herein, the
present invention contemplates and claims those inventions
resulting from the combination of features of the invention cited
herein and those of the cited prior art references which complement
the features of the present invention. Similarly, it will be
appreciated that any described material, feature, or article may be
used in combination with any other material, feature, or article,
and such combinations are considered within the scope of this
invention.
[0352] The disclosures of each patent, patent application, and
publication cited or described in this document are hereby
incorporated herein by reference, each in its entirety, for all
purposes.
* * * * *
References